Assembly Supervisor

Assembly Supervisor

We are seeking an experienced Assembly Supervisor to lead a team in a low-volume, high-mix electrical and mechanical assembly environment. This role is responsible for the daily direction of assembly operations, ensuring safety, quality, and delivery targets are met while driving continuous improvement through lean manufacturing principles. The ideal candidate has hands-on experience balancing frequent product changeovers, complex build configurations, and shifting priorities — while still delivering consistent throughput and quality.

Key Responsibilities

• Supervise, coach, and develop a team of assembly technicians across multiple product lines and build configurations
• Create and maintain training matrices; ensure operators are cross-trained to support high-mix production flexibility
• Conduct daily shift start-up meetings, communicate priorities, and hold team accountable to safety, quality, and productivity standards
• Manage timekeeping, performance reviews, disciplinary actions, and staffing/scheduling needs

Production & Material Flow

• Own daily production schedules across a mix of low-volume, custom, and configurable builds; adjust staffing and sequencing to meet changing demand
• Drive material flow improvements between receiving, kitting, and the assembly line to minimize downtime, WIP, and staging bottlenecks
• Partner with Materials/Planning to ensure kit accuracy, on-time component availability, and appropriate inventory levels (min/max, kanban, point-of-use) for high-mix SKUs
• Utilize ERP/MRP systems (SAP S/4HANA preferred) for order status, inventory transactions, work order closure, and production reporting

Line Balancing & Process Improvement

• Perform time studies and line balancing activities to optimize labor allocation across variable product mixes
• Identify and eliminate bottlenecks, non-value-added steps, and process variation using lean tools (5S, value stream mapping, standard work, kaizen events)
• Lead or support setup/changeover time reduction (SMED) initiatives to improve flexibility across frequent product/model changes
• Collaborate with Industrial/Manufacturing Engineering on layout changes, workstation design, and process documentation

Quality & Defect Reduction

• Monitor first-pass yield, defect rates, and rework/scrap metrics; lead root cause analysis (5 Why, fishbone, 8D) for recurring issues
• Partner with Quality Engineering to implement corrective/preventive actions (CAPA) and error-proofing (poka-yoke) at the workstation level
• Ensure adherence to work instructions, build travelers, and engineering specifications for electrical and mechanical sub-assemblies
• Champion a culture of built-in quality, encouraging operators to stop and escalate issues rather than pass on defects

Problem Solving & Continuous Improvement

• Use structured problem-solving methods (PDCA, A3, DMAIC) to address daily production issues and drive sustainable corrective actions
• Track and report key performance indicators (safety, quality, delivery, cost, productivity) and lead daily/weekly tier meetings
• Actively participate in and lead continuous improvement (kaizen) initiatives, targeting productivity, flow, and cost reduction
• Support new product introduction (NPI) and engineering change implementation on the assembly floor

Required Qualifications

• 5+ years of manufacturing supervisory experience, with direct experience in low-volume, high-mix assembly environments
• Demonstrated experience with electrical and mechanical assembly processes (wiring, harnessing, fastening, sub-assembly integration, etc.)
• Hands-on knowledge of lean manufacturing principles: 5S, standard work, kaizen, value stream mapping, SMED, poka-yoke
• Proven track record in line balancing, material flow optimization, and inventory/kitting management
• Experience leading root cause analysis and defect/scrap reduction initiatives
• Strong people leadership skills: training and development, performance management, and conflict resolution
• Working knowledge of ERP/MRP systems (SAP S/4HANA or similar) for production and inventory transactions
• Ability to read and interpret engineering drawings, wiring diagrams, BOMs, and work instructions
• Strong communication skills across shifts and cross-functional teams (Engineering, Quality, Materials, Planning)

Preferred Qualifications

• Bachelor's degree in Industrial/Manufacturing Engineering, Operations Management, or related field (or equivalent experience)
• Lean Six Sigma Green Belt or Black Belt certification
• Experience in automotive, industrial equipment, or similarly regulated/high-mix manufacturing sector
• Experience with SAP S/4HANA Production, Quality, and Materials modules
• Familiarity with IPC or J-STD standards for electrical/wire harness assembly (if applicable)

Physical Requirements / Work Environment

• Ability to work on a manufacturing floor, including standing/walking for extended periods
• Ability to lift up to 35 lbs occasionally
• Flexibility to support multiple shifts or occasional off-shift coverage as production needs require

The Coats Company is an equal opportunity employer that evaluates qualified applicants without regard to race, color, national origin, religion, ancestry, sex (including pregnancy, childbirth and related medical conditions), age, marital status, disability, veteran status, citizenship status, sexual orientation, gender identity or expression, and other characteristics protected by law.