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Operational Excellence Specialist - Equipment Reliability

Job
Summary:
The Company is a privately-held, global leader in aluminum rolled and extruded products, and aluminum recycling. Headquartered in Cleveland, Ohio, the company operates more than 40 production facilities in North America, Europe and Asia.
We are seeking to add a talented Operational Excellence Specialists - Reliable Assets to our Business System team at our plants in Lewisport, KY; Uhichsville, OH; Davenport, IA; and Richmond, VA. The purpose of this role is to be a lead Business System team member on the implementation, training, teaching, coaching, and management of a world class continuous improvement system utilizing lean and six sigma techniques in the plants. The role will require approx. 10% travel to various sites in North America. This position is a key support and tactical execution role of one of the cornerstones of our Business System - Reliable Assets (Equipment).

Responsibilities Include:
Support the implementation of a world class Business System: Reliable People (Lean Operations), Reliable Process (APC) and Reliable Assets (Equipment).
Teach and train the Business System curriculum for Engineers, technical support, operations, maintenance and staff throughout the facility.
Provide coaching and mentorship of plant teams in the impact they have on equipment reliability.
Support the development of the plant Reliability Roadmap, maintain the map.
Support the development the plant Reliability Centered Maintenance program
Provide coaching on condition based maintenance: Oil Analysis, Vibration Analysis, Infrared Imagining and Analysis, PDMA etc.
Precision Maintenance: Laser Alignment, Lubrication Routes, Roll Management etc.
PM (Preventative Maintenance)and PdM (Predictive Maintenance) systems.
Asset Care Plans.
Work Request, Work Management and Notification systems.
Material Management, Spares and stores storage systems.
Support the Plant and Regional Managers of Reliable Operations, Reliable Process and Reliable Assets through project work and data analysis.
Support the plant teams through facilitation and participation of advance problem solving techniques.
Demonstrate effective team facilitation skills to engage the various teams to deliver improvement results on time.
Implement the standardized Business System toolbox, including core tools: 5s, A3 Thinking, SMED, RCFA, TWI, Standardized Work, VSM, TPM, APC, Equipment Reliability and Problem Solving.
Coach/facilitate/participate in plant shopfloor teams to enable the company to continuously improve performance, leverage Information Centers for continuous improvement, and create a visual workplace, solve complex problems.
Interface with plant, regional and global reliability resources and external consultants to benchmark and develop and closes gaps in the area of equipment reliability.
Develop and participate in Reliability auditing at all levels of the organization. Make recommendations and drive to implementing sustainable solutions.
Work with project engineering to ensure Design for Reliability concepts have been incorporated to ensure the maintainability of new and modified installations by using the life cycle asset management process.
Assist leadership in the development of strategic A3s for the business and plants.
Coordinate event follow-up (30/60/90 day reviews) to monitor the progress of planned improvement implementation to assure timely action, appropriate management support, and achievement of expected tangible benefits.
Lead/facilitate projects and/or events which address value-at-stake opportunities, helping to drive improvements in all facets of operations.
Participate in Business System and HSE audits. Drive solution implementation.
Identify and focus on short and long-term wins that will transform the culture and produce results.
Lead Root Cause Failure Analysis of significant People, Process, Equipment related downtime events at Plant locations; implementing permanent corrective actions to mitigate probability of reoccurrence.
Facilitate FMEA(Failure Mode Effect Analysis) on equipment and processes within the facility.
Preform Analysis of Equipment Performance
Use statistical analysis techniques in the development of solutions to repetitive equipment failures and other equipment problems.
Coordinate the development, implementation and review the asset management strategy for each critical asset in the manufacturing unit.
Be a leader within the Business System organization - engage the workforce.
Openly and effectively communicate about continuous improvement, build credibility through relationships, and provide leadership to the program.
Be a resource for operations, maintenance, HSE and supply chain in support of delivering the business objectives.
Use, teach and coach lean and six sigma methodology and proactive problem solving.
Spend 75% of working time at Gemba (on the plant floor) focusing on employee engagements.

Requirements Include:
Bachelor's degree strongly desired, preferably in engineering, manufacturing/operations; or an equivalent level of degree/experience.
2+ years of experience facilitating, coaching and implementing TPM, Lean, kaizen/six sigma events and driving lean transformation with proven results and implementations in a manufacturing environment.
Proven ability to work independently and successfully facilitate cross functional teams, while implement improvement within an established time frame.
Well Organized, High energy, data driven, and results oriented.
Excellent interpersonal, written, verbal communication skills and organization skills, must be comfortable teaching and presenting to large groups at all levels of the organization from shopfloor to CEO.
Must be proficient in MS Word, MS Excel, MS PowerPoint, MS Project, Oracle, and various analysis tools (minitab, etc).
Willingness to travel approximately 10% of the time.

Preferred Qualifications:
Aluminum Casting or Rolling Experience.
Six Sigma Green/BlackBelt training/certification.
CMRP or SMRP certification.
Process/Technical/Operations/Maintenance experience.

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