Machine Shop Manager

We are looking for a seasoned Machine Shop Manager to spearhead our machining operations at Rapsri Engineering Products Company (REPCO). In this pivotal role, you will oversee a team of 100 operators and manage a diverse array of CNC turning machines and VMCs, ensuring the efficient machining of copper, brass, and bronze castings and forgings. Your primary focus will be to elevate our machining technology through the introduction of hydraulic fixturing, auto gauging systems, and robotic pick-and-place solutions. You will drive productivity improvements by implementing bottleneck analysis, single-piece flow methodologies, and CNC program optimization. A key aspect of your role will be reducing machining defects through the implementation of statistical quality control and operator self-inspection programs. You will champion flexible and lean manufacturing principles, facilitating frequent layout changes and optimizing workflows. The ideal candidate will be a dynamic leader with a proven track record in high-mix, medium-volume production environments, capable of driving significant enhancements in efficiency, quality, and cost-effectiveness.

Responsibilities:

Operational Leadership and Management

• Lead and manage a team of 100 operators within the machine shop, fostering a culture of continuous improvement and high performance.
• Oversee daily operations, ensuring efficient workflow, optimal resource utilization, and adherence to production schedules.
• Develop and implement strategies to improve overall equipment effectiveness (OEE) and reduce downtime.
• Manage the machine shop budget, monitoring expenses, and identifying cost-saving opportunities.
• Ensure compliance with safety regulations and company policies within the machine shop environment.
• Conduct regular performance reviews and provide coaching and development opportunities for team members.

Technology Enhancement and Automation

• Spearhead the introduction of advanced machining technologies, including hydraulic fixturing, auto gauging systems, and low-cost automation solutions.
• Evaluate and implement robotic pick-and-place systems to improve efficiency and reduce manual handling.
• Collaborate with engineering and maintenance teams to optimize CNC programs and tooling for enhanced performance.
• Identify and implement opportunities for automation to reduce manpower requirements and improve throughput.
• Research and recommend new equipment and technologies to improve machining capabilities and efficiency.
• Oversee the integration of CAD/CAM software to streamline the design and manufacturing process.

Process Improvement and Defect Reduction

• Implement lean manufacturing principles, including bottleneck analysis, single-piece flow, and SMED methodology, to optimize production processes.
• Introduce statistical quality control (SQC) and operator self-inspection programs to minimize machining defects.
• Conduct root cause analysis of defects and implement corrective actions to prevent recurrence.
• Optimize machining cycle times through CNC program optimization and combination cutting tools.
• Develop and maintain process documentation to ensure consistency and adherence to quality standards.
• Implement a preventive maintenance program to ensure the reliability and longevity of machining equipment.

Quality Control and Assurance

• Establish and maintain quality control standards for all machining operations, ensuring adherence to customer specifications and industry best practices.
• Implement and monitor key performance indicators (KPIs) to track quality performance and identify areas for improvement.
• Oversee the calibration and maintenance of measuring equipment to ensure accuracy and reliability.
• Conduct regular audits of machining processes to identify and address potential quality issues.
• Collaborate with the quality assurance team to resolve customer complaints and implement corrective actions.
• Ensure compliance with Geometric Dimensioning and Tolerancing (GD&T) standards in all machining operations.

Cross-Functional Collaboration and Stakeholder Management

• Collaborate with engineering, procurement, and sales teams to ensure alignment of production plans with customer demand.
• Work closely with suppliers to ensure timely delivery of high-quality materials and tooling.
• Communicate effectively with stakeholders at all levels of the organization to provide updates on machine shop performance and initiatives.
• Participate in cross-functional teams to address process improvement opportunities and resolve technical issues.
• Liaise with external vendors and consultants to evaluate and implement new technologies and best practices.
• Negotiate contracts with suppliers and service providers to ensure cost-effectiveness and quality.

General Expectations and Past Experiences:

• Possess 15-20 years of progressive experience in machine shop management, with a strong focus on CNC machining of copper, brass, and bronze.
• Demonstrated expertise in lean manufacturing implementation, including bottleneck analysis, SMED, and single-piece flow methodologies.
• Proven ability to lead and motivate a large team of operators in a high-mix, medium-volume production environment.
• Strong technical skills in CNC programming, tooling management, and fixture design.
• Experience in implementing automation technologies, including robotic pick-and-place systems and auto gauging systems.
• Proficiency in CAD/CAM software and statistical quality control techniques.
• Excellent communication, problem-solving, and decision-making skills.