Process Coach – Maintenance | Diesel Head Machining, 6.7L Engine Program
Department
Powertrain Manufacturing – Machining Operations
Reports To
Maintenance Manager / Area Manager, Diesel Head Machining Manager
Direct Reports
6 Maintenance Technicians (direct) | 50+ Production Team Members (indirect/matrixed collaboration)
The Process Coach – Maintenance is responsible for leading the maintenance strategy, technical direction, and daily execution of equipment reliability within the Diesel Head Machining area for the 6.7L engine program. This role owns the health and performance of high-complexity automated systems, including Schneider PLC-controlled assembly machines, mechanical and hydraulic systems, lift-assist devices, gantry systems, MAG 4-axis CNC machines, Eco Clean washing systems, and Marposs / JW Froelich final assembly and gauging equipment. The Process Coach will drive equipment reliability, lead a team of technicians, support new equipment installation and validation, and partner with Production to deliver results across all critical metrics: Safety, Quality, Delivery, Cost, People, and Maintenance (SQDCPM).
This is a hands-on leadership role requiring strong technical expertise, people management skills, and a continuous improvement mindset grounded in TPM, Lean Manufacturing, and Six Sigma methodologies.
ResponsibilitiesKey Roles & Responsibilities
1. Team Leadership & People Management
Directly supervise, coach, and develop a team of 6 maintenance technicians across assigned shifts.
Provide functional leadership and cross-collaboration with 50+ indirect production team members to ensure alignment on equipment performance and issue resolution.
Manage schedules, training plans, skill matrices, and performance evaluations for the maintenance team.
Foster a culture of safety, accountability, discipline, and continuous improvement.
Provide availability and flexibility to support multiple shifts, weekends, and emergency call-outs as required by production demands.
2. Equipment Reliability & Technical Ownership
Own the reliability strategy for assembly machines with Schneider PLC controls, mechanical/hydraulic systems, lift-assist units, and gantry systems.
Provide technical leadership for MAG 4-axis CNC machines, Eco Clean washer systems, and Marposs/JW Froelich final assembly and gauging equipment.
Lead root cause analysis (RCA) and problem-solving activities (5 Why, Fishbone, 8D) for chronic equipment failures.
Drive predictive and preventive maintenance (PM) programs to maximize equipment uptime and reduce unplanned downtime.
Analyze machine downtime data, MTBF/MTTR trends, and reliability metrics to identify improvement opportunities.
3. TPM, Lean Manufacturing & Continuous Improvement
Champion Total Productive Maintenance (TPM) pillars, including Autonomous Maintenance and Planned Maintenance, in collaboration with Production.
Apply Lean Manufacturing principles to reduce waste, improve process flow, and optimize maintenance response times.
Utilize Six Sigma tools and methodology (DMAIC) to lead structured problem-solving and process improvement projects.
Support and lead Kaizen events focused on equipment reliability, changeover reduction, and maintenance efficiency.
4. New Equipment Implementation & Validation
Lead the installation, commissioning, and validation of new equipment and process upgrades within the head machining area.
Coordinate Run-at-Rate, capability studies, and equipment buy-off activities with Engineering, Quality, and Manufacturing teams.
Develop and validate PM plans, spare parts strategies, and technical documentation for new equipment prior to production launch.
Ensure new equipment integration aligns with plant safety, ergonomic, and quality standards.
5. Metrics Management (SQDCPM)
Partner with Production leadership to manage and improve daily/weekly metrics: Safety, Quality, Delivery, Cost, People, and Maintenance.
Lead daily tier meetings, reporting equipment status, action plans, and escalation of critical issues.
Track and report KPIs such as OEE, downtime, PM compliance, MTBF/MTTR, and cost per unit.
Develop corrective action plans when metrics deviate from targets and drive accountability for closure.
6. Safety & Compliance
Ensure all maintenance activities comply with plant safety standards, lockout, and environmental regulations.
Promote a zero-incident safety culture within the maintenance team and area.
Ensure equipment modifications and repairs maintain compliance with engineering and safety specifications.
QualificationsIdeal Qualifications
Education
- Bachelor's degree in Mechatronics, Industrial, Electrical, Mechanical Engineering, or related technical field (required).
- Certifications in TPM, Lean Manufacturing, or Six Sigma (Green Belt/Black Belt preferred) are highly valued.
Experience
- Minimum 5–7 years of experience in maintenance within an automotive manufacturing environment, ideally in machining or powertrain operations.
- Proven experience leading maintenance teams (direct reports) in a high-volume production environment.
- Hands-on experience with PLC-based control systems (Schneider preferred), CNC machining centers, hydraulic/mechanical systems, and automated assembly/gauging equipment.
- Experience with new equipment installation, validation, and Run-at-Rate processes.
- Demonstrated experience managing plant-level metrics (SQDCPM) in partnership with Production.
Technical Skills
- Strong knowledge of TPM principles (Autonomous & Planned Maintenance pillars).
- Working knowledge of Lean Manufacturing tools (5S, Kaizen, Value Stream Mapping, SMED).
- Six Sigma methodology and statistical problem-solving skills (DMAIC, root cause analysis).
- Proficiency in reading electrical schematics, hydraulic diagrams, and PLC logic (Schneider platform preferred).
- Familiarity with CMMS systems for maintenance planning and tracking.
Leadership & Soft Skills
- Strong people leadership skills with the ability to coach, develop, and hold technicians accountable.
- Ability to influence and collaborate cross-functionally with Production, Quality, and Engineering teams.
- Strong analytical and decision-making skills under pressure.
- Excellent communication skills, both written and verbal.
- Bilingual (Spanish/English) preferred, depending on plant requirements.
Availability
- Flexibility to work rotating shifts, weekends, and respond to off-hours emergencies as needed by production demands.
Skills Required
- Bachelor's degree in Mechatronics, Industrial, Electrical, Mechanical Engineering, or a related technical field
- 5-7 years of maintenance experience in automotive manufacturing, preferably machining or powertrain operations
- Experience leading maintenance teams with direct reports in a high-volume production environment
- Hands-on experience with PLC-based control systems, CNC machining centers, hydraulic and mechanical systems, and automated assembly or gauging equipment
- Experience with new equipment installation, validation, Run-at-Rate, and equipment buy-off processes
- Experience managing plant-level safety, quality, delivery, cost, people, and maintenance metrics
- Knowledge of TPM principles, including Autonomous Maintenance and Planned Maintenance
- Working knowledge of Lean Manufacturing tools, including 5S, Kaizen, Value Stream Mapping, and SMED
- Knowledge of Six Sigma methodology, DMAIC, and statistical root-cause analysis
- Ability to read electrical schematics, hydraulic diagrams, and PLC logic
- Familiarity with CMMS systems for maintenance planning and tracking
- TPM, Lean Manufacturing, or Six Sigma certifications, including Green Belt or Black Belt
- Bilingual Spanish and English communication skills
- Flexibility to work rotating shifts, weekends, and off-hours emergency call-outs
Ford Motor Company Compensation & Benefits Highlights
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Healthcare Strength — Eligible employees can access medical, dental, and prescription coverage starting on the first day, with some zero-cost plan options and free mental health support. Benefits materials highlight comprehensive healthcare as a core pillar.
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Retirement Support — Employees can enroll in a 401(k)-style plan from day one, and some salaried plans include a company match of $0.90 per dollar on the first 5% contributed. Official summaries also describe financial-planning support.
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Parental & Family Support — The package includes paid parental leave, fertility, surrogacy, and adoption benefits, plus a ramp-up program for new parents returning to work. Flexible family-care days and other time-off options support caregiving needs.
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What We Do
Ford is a global company with shared ideals and a deep sense of family. From our earliest days as a pioneer of modern transportation, we have sought to make the world a better place – one that benefits lives, communities and the planet. We are here to provide the means for every person to move and pursue their dreams, serving as a bridge between personal freedom and the future of mobility. In that pursuit, our 186,000 employees around the world help to set the pace of innovation every day.
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