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Maintenance Manager

Job Number:  10267
Group:  Cosma International
Division:  Cosma USA Group Office
Job Type:  Permanent/Regular

Detroit, MI, US, 48212





Job Number: 10267 
Group: Cosma International  
Division: Cosma USA Group Office 
Job Type: Permanent/Regular 
Location: Detroit 




Group Description


Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.



Role Summary

The Maintenance Manager directs the maintenance activities for the division. The Maintenance Manager oversees and monitors all maintenance activities for: the installation, repair and upkeep of the machinery/equipment and plant including mechanical systems and other structures; supporting management/supervision/maintenance personnel by acting as liaison in matters regarding policy/process application, manpower scheduling, employee relations; continuous improvement related to maintenance functions and energy usage; and the contractor program. The Maintenance Manager directly or indirectly oversees the functions of approximately 25-30 persons as well as contracted personnel. The Maintenance will provide technical welding expertise to all applicable areas of the division. The Maintenance Manager is responsible for the evaluation and recommendations associated with new and existing programs as it relates to weld assembly processing, tooling and equipment. The Maintenance Manager will maintain weld parameters for: the new/existing equipment; weld schedules.

Key Responsibilities

• Initiate, implement, and manage the plant maintenance program based on best practices in the automotive manufacturing industry, with an emphasis on planning/scheduling and preventive/predictive maintenance.
• Responsible for short term/long term planning and scheduling regarding machinery/equipment maintenance optimization.
• Develops programs for record retention (machinery/equipment/facility repairs), preventative maintenance, build standards, job training, etc. for the Maintenance/Facilities function.
• Researches and obtains cost quotes for plant/facility new equipment/systems as required.
• Participates in equipment/machinery and plant layout initiatives.  Actively participates in design and development of methods and equipment.
• Plan, organize, direct, control and evaluate contractor/construction projects.
• Actively participates in scheduling meetings with production to prioritize work orders, optimum downtime windows, and necessary lead times.
• Coordinate plant activities with the operations departments and assist with planning and implementing plant improvements and expansions as required.
• Tracks, analyses and improves key maintenance parameters such as asset utilization, maintenance cost, PM compliance, schedule compliance, etc.
• Direct and support the maintenance department personnel in the maintenance and repair work of the equipment/machinery/building throughout the division.
• Develops department action plan and leads their team to achieve strategic goals and continuous improvement objectives in alignment with the Company’s Vision and Guiding Principles.
• Improve on and implement a training program for all Weld Tech’s to upgrade their skill levels.
• Manage and coordinate all Weld Tech and Weld Tech apprentice schedules and work duties.
• Provide technical welding expertise to division personnel to support existing and new customer programs.
• Lead all root cause investigations into weld related defects and lead the team to full resolution and lessons learned.
• Develop and implement documents and procedures for validation of welding equipment and processes to meet or exceed customer specifications and provide guidance and input for the setup and programming of robots for welding best practices.
• Participate in APQP/CPMP processes relating to the design of weld assembly work cells and tooling, make recommendations as required.

Key Responsibilities (Continued)

 Evaluate processes/equipment and make continuous improvement recommendations in the weld quality and process.
• Develop, and implement a training program for skilled trades and assigned personnel in robotic and hand; Projection, Spot and GMAW welding techniques and procedures and in the troubleshooting and repair of robotic and manual welding equipment.
• Recommend design changes to improve quality, reliability and productivity of welding equipment/process.
• Conducts performance reviews informally or formally as required and ensures performance reviews are completed for all employees.
• Work to achieve Company goals, objectives as communicated by divisional leadership.
• Complies with, supports and models Magna operational procedures/policies, Employee Handbook, and Magna’s Employee’s Charter, Corporate Constitution, and Operational Principles.
• Complies with relevant Quality and Environmental programs (e.g. TS16949, ISO14001).
• Complies with all Health and Safety programs in accordance with OSHA. Follows and ensures Company procedures regarding safety rules and regulations are followed.
• Possesses excellent verbal and written communication skills.
• Conducts themselves in a professional manner.
• Keeps work area clean and tidy.
• Other duties as required.

Key Qualifications/Requirements

• 4-year Weld Engineering Degree or University degree in: Mechanical/Electrical Engineering, or Certification of Qualification for Electrical/Millwright equivalent with extensive welding knowledge
• Minimum 5-7 years’ experience in an automotive welding engineering, design and program development environment
• Extensive knowledge of automotive welding (familiarity with; Fanuc, Bosch, Fronius, Tregaskiss, Milco, DCMF) and fabrication processes (RSW, GMAW, GMAB, Projection welding)
• Familiar with Advanced Product Quality Planning methods
• Familiarity with Engineering and Quality practices and procedures including PPAP, blueprint reading, GD&T, use of measuring instruments, checking aids/fixtures, mechanical testing, etc.
• Experience/knowledge in robotic programming for welding processes (Fanuc programming an asset)
• Familiarity with electrical, hydraulic and pneumatic equipment
• Knowledge of GM weld standards and specifications
• Knowledge of AWS and RWMA standards
• Computer skills in Microsoft office
• Ability to prepare, read, write, and interpret written reports, procedures, instructions and guidelines
• Demonstrate a maturity of judgement, leadership skills, attention to detail and exceptional organizational, listening, communication and presentation skills in all aspects of the job function.
• Excellent math skills with the ability to apply to cost and analyze data.
• Ability to analyze and troubleshoot equipment, processes, etc.
• Ability to work flexible hours in a fast-paced environment in order to meet customer requirements
• Must be able to interact effectively with other team members
• Able to appreciate and maintain proper level of confidentiality, using discretion and tact.

Additional Information

The Maintenance Manager works independently and confers regularly with division, corporate, contractors, customer, and supplier staff specialists.  The Maintenance Manager must combine his/her technical, human, and conceptual skills to plan, control and lead the maintenance/facilities team toward meeting divisional goals and objectives.  A valid Driver’s License is required for day travel with the occasional overnight stay.  A valid passport which allows the Maintenance Manager to travel to attend customer and potential integrator/supplier meetings is necessary.  Travel and overtime may be required to meet customer expectations.  The incumbent requires excellent communication skills, both verbal and written and some of the information in-process can be considered confidential.  The Maintenance Manager works in an office environment but may be exposed to some elements such as temperature and noise during time spent in the plant.

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