Quality Control Group Leader

Toyota Boshoku America•Lawrenceville, IL

1d•Onsite

About The Position

Under general supervision, oversees quality control operations during the designated shift, maintains the plant quality system, and manages daily job assignments. Directs Team Leaders and Team Members in an assigned manufacturing area and manages the group as an operational unit to meet company goals and targets for safety, product quality, customer satisfaction, accuracy, productivity, cost reduction, housekeeping, efficiency, training, teamwork, and morale. The role supports the Quality Manager and plant quality system, establishes and maintains customer-focused quality standards, and coordinates quality problem investigation, containment, and corrective action. The position supervises staffing, performance, training, production, safety, quality, continuous improvement, communications, and administrative records for the assigned area. It applies Toyota Production System techniques and Toyota Boshoku Business Practices to standardize processes, reduce variation and waste, address abnormalities, and maintain stable, efficient operations. The role also requires collaboration with customers, suppliers, manufacturing, production control, quality control, and other departments to resolve quality issues. The work takes place in an open office and various manufacturing environments, including a standard automotive plant with moderate noise and occasional exposure to cold, dust, heat, or odor. Required protective equipment may include safety glasses, steel-toe shoes, Kevlar sleeves, and hearing protection. Travel is minimal. The job involves sustained attention, equipment inspection and operation, extended walking, sitting, and standing, occasional climbing, stooping, bending, reaching, grasping, and manipulating parts or equipment, and occasional lifting of up to 30–50 pounds, with or without assistance.

Requirements

High school diploma, GED, or equivalent required.
Associate’s degree required, or an equivalent combination of education and experience.
At least three years of relevant manufacturing experience.
At least two years of leadership or supervisory experience.
Demonstrated knowledge, skills, and abilities to perform leadership job functions.
General understanding and practical experience with automotive quality systems and processes.
General understanding and working knowledge of inspection standards and check fixtures.
Ability to work a fixed or rotating shift schedule, including daily or weekend overtime.
Thorough understanding of company products, trade terminology, quality management and control systems, manufacturing processes, material controls, workflow, scheduling, kanban, machine operation, and company policies and standards.
Basic math and analytical skills and the ability to facilitate problem solving and resolution.
Ability to work with a dynamic team and demanding customers in a fast-paced, multicultural environment.
Ability to work across departments, prioritize activities, plan and supervise assigned functions, and remain flexible in a changing production environment.
Ability to maintain on-call flexibility to control abnormal conditions.
Effective leadership, listening, verbal and written communication, and interpersonal skills; strong English skills required.
Ability to multitask, handle diverse situations, and lead problem resolution while working with all organizational levels in a team environment.
Ability to adapt available skills and equipment to unforeseen demands or problems and implement plans for safety, quality, 5S, cost, and efficiency.
Strong organization, time management, and planning skills, including the ability to manage multiple tasks with tight deadlines.
Ability to teach basic fundamental skills to Team Leaders and Team Members and facilitate Job Instruction Training.
Ability to read instruction manuals, blueprints, and specifications.
Previous experience with integrated computer programs or applications and solid working knowledge of Microsoft Office and other computer-based applications.
Willingness to complete required training and certifications for forklift, tugger, and truck use; overhead crane operation; cross-training for plant support departments; RCRA and DOT hazardous waste requirements; and computer-based systems.

Nice To Haves

Bachelor’s degree preferred.
Automotive industry experience, particularly in parts production, quality, or production control.
Working knowledge and experience with Toyota Production System (TPS) and Production Efficiency (PEFF).
ERP system experience, such as Oracle.

Responsibilities

Oversee quality control operations during the assigned shift and support the overall plant quality system.
Supervise Team Leaders and Team Members, assign and reassign work, coordinate staffing with the Assistant Manager, and monitor staffing, hours, overtime, rotation, and absenteeism.
Manage and appraise team member performance, recommend corrective action, and promote positive team member relations and two-way communication.
Lead the manufacturing and production system in the assigned area and work toward department goals, schedules, and targets.
Use Toyota Production System techniques and Toyota Boshoku Business Practices to standardize processes, reduce variation and waste, and correct substandard conditions.
Develop and document standardized work procedures and direct work assignments based on production requirements and schedules.
Maintain the flow of parts and materials, productivity, quality, kanbans, and inventory; take corrective action as needed.
Ensure quality standards and procedures are followed, use quality feedback and escalation systems, and partner with the Quality department on investigations and containment.
Communicate customer or supplier quality issues to relevant departments and work with customers and suppliers to resolve quality problems.
Investigate internal defects and implement countermeasures to prevent further defect outflow and improve plant processes.
Troubleshoot daily quality, safety, and production issues; anticipate abnormalities and coordinate equipment and machinery repairs.
Lead continuous improvement and participate in KPI setting, tracking, and improvement projects involving safety, quality, operational availability, productivity, scrap, and cost.
Maintain KPI boards and graphs, implement team member suggestions and management initiatives, and support safety, quality, productivity, and cost improvements.
Maintain a safe workplace and ensure compliance with safety regulations, PPE requirements, company procedures, and policies.
Lead or participate in ergonomic activities, 5S housekeeping, accident investigations, safety audits, and workstation assessments; implement countermeasures and job rotation.
Maintain knowledge of hazardous waste, spill response, and plant security procedures, and monitor team member health and safety.
Train, coach, and develop team members; oversee orientation, cross-training, training plans, training effectiveness, and training matrices.
Prepare and maintain department instruction manuals, business reports, spreadsheets, production and quality records, and team member time, attendance, and training records.
Communicate with internal contacts, keep team members informed through regular meetings, coordinate with upstream, downstream, and support groups, and coordinate communications between shifts.
Perform Team Leader or Team Member duties as needed to maintain efficient, stable, and continuous operations.