Gears Process Coach - Planta Ford Irapuato

Reporting directly to the Production Team Manager, the Gears Process Coach acts as the first line of leadership and support on the manufacturing floor. In this position, you will be the owner of the DCP (Daily Continuous Production) execution and will manage the pace and precision of production. Your main mission will be to guarantee a 100% safe work environment, ensure strict adherence to Standardized Work, apply the FPS (Ford Production System), and lead the rapid response to any operational abnormality (AR).

You will work hand in hand with Process, Quality, Maintenance, and Labor Relations Engineers to solve problems using methodologies such as 8D and POKAR, optimize shift resources, and develop your team's skills through the versatility matrix and daily coaching.

Safety:

• Act as the absolute owner of operator safety during the shift and be the first line of response to incidents or near-misses.
• Ensure daily compliance with ECPL (Energy Control and Power Lockout), ergonomics, chemical management (oils, coolants), use of PPE, and adherence to Ford Safety Values.
• Conduct daily Safety Talks, Safety Walks through the area, and follow up on safety Abnormality Reports (POKAR).

Quality:

• Exercise the authority to stop the line in the event of quality issues and coordinate the immediate containment of non-conforming material.
• Execute process observations and Layered Process Reviews (LPR) on the floor to ensure compliance with Control Plans and Standardized Work.
• Actively participate in problem-solving (8D) and execute post-event product release in conjunction with Engineering.

Delivery & Cost:

• Ensure compliance with the production plan (DPR) and manage operational priorities between the Green/HT, Hard, and Ring areas.
• Lead the response to Andon and the escalation of major downtimes.
• Control scrap, rework, use of consumables (tools, coolants), and optimize the use of labor and overtime during the shift.
• Identify improvement opportunities through Kaizen events.

Maintenance:

• Be the first line of detection for equipment abnormalities and raise tickets to Maintenance (CMMS/Maximo).
• Ensure operators execute Level 1 TPM (cleaning, lubrication, basic inspection).
• Coordinate preventive maintenance (PM) windows with the Maintenance Process Coach.

People & Leadership:

• Directly supervise unionized personnel, managing the Operational Shift Planning (PJO), versatility matrix, and vacations.
• Ensure 100% accurate entry in the DROT system (attendance, tardiness, overtime).
• Provide daily coaching, manage discipline in coordination with Human Resources/Labor Relations, and administer the personnel e-file.

• Education: Bachelor's degree in Mechanical, Industrial, Manufacturing, Mechatronics Engineering, or a related field.
• Experience: Minimum 5 years of proven experience in manufacturing, with at least 2 years working as a floor supervisor or coach. (Experience in gear processes or precision machining is highly desirable).
• Languages: Native Spanish and intermediate English (B1/B2) capable of maintaining technical reading and basic communication with global leadership.
• Technical Skills: Knowledge of gear manufacturing processes (hobbing, shaping, grinding, honing, heat treat, gear measurement), blueprint reading, GD&T, and interpretation of Control Plans and PFMEA.
• Functional Skills: Mastery of Ford Production System (FPS), Daily Management System, Standardized Work, problem-solving (8D, 5 Whys, Ishikawa), and Lean Manufacturing.
• Leadership: Solid experience in managing unionized personnel, conflict resolution, effective communication, and change management.
• Availability: Capacity and willingness to rotate shifts according to manufacturing needs.