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World Class Manufacturing Engineer

Job Number:  10357
Group:  Cosma International
Division:  Cosma USA Group Office
Job Type:  Permanent/Regular

Detroit, MI, US, 48212





Job Number: 10357 
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 World Class Manufacturing (WCM) Manager champions the development and accelerates the implementation of division’s world class manufacturing and continuous improvement strategy, promoting employee engagement and driving quality, process and productivity improvement. The WCM Manager oversees MAFACT implementation throughout division and is responsible for reporting on its progress in achieving benchmark world class manufacturing and continuous improvement that result in the highest MAFACT scores. This position is for a greenfield facility located in Southeast Michigan.

Key Responsibilities

• Guides division in determining the priorities for process and productivity improvements that impact production and business results and champions waste elimination and reduction projects.
• Collaborates with Functional Managers (Engineering, Production, Quality, Maintenance, Purchasing, Finance and Human Resources) to assist in developing, prioritizing and executing Division’s annual WCM and CI strategy.
• Actively and regularly reviews Division’s practices to identify opportunities and advise on appropriate organizational interventions (i.e., training, coaching, etc.) for improving Division systems and practices to achieve desired outcomes.
• Initiates and drives Continuous Improvement activities to improve performance including environment, people, processes and equipment/machinery and which also includes the development of procedures and methods to improve safety, quality, timing, cost and motivation.
• Champions annual cost task for Division with Continuous Improvement (CI) coordination.
• Champions division’s overall MAFACT plan, implementation and continuous improvement.
• Monitors progress to continuous improvement KPIs and advances the transformation to world class over time through continued improvement and coaching.
• Champions VSM and Kaizen events.
• Drives lean training and implements a lean toolkit utilizing PDCA, VSM, Kaizen, problem solving, 5S, etc.
• Assists the Production Department with work cell balancing and optimization both prior to and during production.

Key Responsibilities (cont.)

• Assists the Materials Department with packaging, material storage/retrieval, and material routing optimization.
• Acts as gate keeper of division’s floor plan layout and overall material flow strategy, ensuring lean methodology and adherence to best and safe practices.
• Integrates all manufacturing and process engineering changes into production.
• Assists with capacity planning to meet future objectives.
• Co-develops burst build and ramp-up plans for launching programs (concurrent with production). Assists production planning using data-driven problem solving techniques to plan and execute efficient material flow and production.
• Champions division’s MES architecture with the goal of providing clear and concise data to management in order to understand the production landscape and educe inefficiencies that require permanent corrective action.
• Develops quotes for capital projects.
• Conducts time study analysis and methods development.
• Prepares drawings and material specifications as required by all departments.
• Prepares reports, charts and other documentation required for engineering records and projects.
• Analyzes manufacturing data and based on the observations, provides guidelines for standard operations.
• Recommends new, replacement or improvement of equipment that maximizes efficiency, ergonomic design and/or economic viability of division’s operations.
• Directs and distributes the work for his/her area of responsibility.
• Ensures proper documentation of processes, equipment, systems, employee relation issues, investigations, etc.
• Conducts regular department meetings to communicate safety, quality, timing, cost and motivation information and to promote involvement in issues affecting employees or their work areas.
• Ensures confidentiality in all matters pertaining to both business and employee relations.
• Observes, understands, teaches, coaches and mentors direct reports for enhancement of knowledge, skills and succession planning.
• Effectively builds and fosters high performing teams by ensuring teamwork within the department.
• Ensures fairness to direct reports, and encourages and participates in the Open Door Resolution Process for employee relation issues.
• Ensures suppliers are performing work safely while in operations work areas/zones when applicable.
• Complies with, supports and models division’s 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.
• Conducts themselves in a professional manner.
• Develops and maintains peer relationships.
• Keeps work area clean and organized.
• Other duties as required.

Key Qualifications/Requirements

• University degree in Industrial, Manufacturing or Mechanical Engineering; Production/Operations Management; or related field; or equivalent work related experience.
• Minimum 5 years manufacturing/operations experience.
• Knowledge and proven skills in World Class Manufacturing and Lean Manufacturing methods.
• Adept at using advanced problem solving techniques and process improvement methodologies; e.g., Six Sigma (DMAIC), flow and process Kaizen, Value Stream Mapping (VSM) and Kepner Tregoe (KT). Related professional certifications (Black Belt, Six Sigma, Lean Champion, KT, etc.) desired.
• Ability to apply standard industrial engineering practices.
• Proficiency in Microsoft Office (particularly MS Excel) and manufacturing operation systems (ERP, MES, etc.).
• Strong math skills with the ability to apply to costs and analyze data.
• Strong listening, communication (verbal and written), and presentation skills.
• Attention to detail and exceptional planning and organizational skills.
• Ability to work well in a fast paced environment and with a variable workload (flexible hours).
• Demonstrated maturity of judgement and leadership skills.
• Must be able to interact effectively with other team members.
• Ability to maintain confidentiality, and use discretion and tact.

Additional Information
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