Rewind Department SupervisorThe Rewind Department Supervisor will oversee all motor winding and rewinding operations at a large-scale electric motor repair facility with 60 total employees at full capacity. This hands-on supervisory role is responsible for leading a team of winding technicians, ensuring high-quality coil construction, maintaining production schedules, and providing technical expertise for all types of AC and DC motor windings, including complex DC armatures and field frames on large DC machines.Pending Start Date: December 2026Key Responsibilities:Team Leadership & SupervisionDirectly supervise 8-15 winding technicians, apprentices, and coil buildersAssign daily work assignments and prioritize jobs based on production scheduleTrain and mentor winders on proper winding techniques, from basic to advancedDevelop apprentice winders through structured training programsConduct performance evaluations and provide ongoing coachingManage attendance, scheduling, and overtime for the rewind departmentFoster a culture of craftsmanship, quality, and continuous improvementTechnical & Production Management:Review and interpret motor nameplates, connection diagrams, and winding data sheetsCalculate winding specifications for motors without available dataDesign and approve coil configurations for standard and custom windingsTroubleshoot winding failures and determine root cause (insulation breakdown, contamination, thermal damage)Perform or oversee complex windings including form-wound coils, multi-speed motors, and special applicationsOversee DC armature rewinding including:Coil removal and slot preparationBar winding and diamond coil construction for large armaturesCommutator riser soldering and undercuttingBanding installation on high-speed armaturesProper balancing requirements and proceduresDirect field frame rewinding for large DC machines including:Series, shunt, compound, and interpole field coil designPole shoe removal and insulation proceduresField coil winding and installationConnection and lead terminationField flash testing and verificationCreate and maintain winding records and connection diagrams for future referenceDetermine wire size, turns per coil, pitch, and insulation requirementsQuality Assurance:Inspect coils before and after installation to ensure quality standardsVerify proper conductor sizing, insulation clearances, and coil dimensionsOversee winding testing including resistance, continuity, hi-pot, and surge testsPerform specialized DC machine testing:Armature bar-to-bar testingCommutator segment isolation testingField coil resistance and polarity verificationGround wall testing on DC windingsDynamic balance testing on armaturesEnsure proper slot insulation, phase insulation, and wedge installationApprove varnish/epoxy treatment processes for windingsMonitor and prevent common defects (crossed coils, incorrect connections, inadequate insulation)Verify DC-specific quality criteria:Proper commutator riser connections and qualityAdequate banding tension and securityCorrect interpole and compensating winding connectionsProper brush positioning and neutral plane alignmentInvestigate and resolve customer quality complaints related to windingsEnsure compliance with EASA AR100 and IEEE 43 standardsMaterials Management:Coordinate with purchasing on magnet wire, insulation materials, and varnish requirementsMaintain adequate inventory of wire sizes, slot liners, phase paper, and wedgesManage DC-specific materials:Approve material substitutions when necessaryMonitor material costs and control wasteEnsure proper storage and handling of insulation materialsManage varnish and resin inventory and mixing proceduresProduction Planning & Scheduling:Work with Production Manager to meet departmental delivery commitmentsBalance workload among winding technicians based on skill level and job complexityEstimate labor hours required for various winding jobsAccount for extended lead times on large DC projects:Complex armature rewinds (multi-day or multi-week projects)Custom field coil fabricationSpecialized testing and balancing proceduresIdentify and communicate production delays or bottlenecksCoordinate with other departments (stripping, machining, assembly) on job handoffsTrack work-in-progress and maintain department flowEquipment & Facility Management:Oversee operation and maintenance of winding equipment including:Coil winding machinesLacing and taping machinesVPI (Vacuum Pressure Impregnation) system or dip-and-bake ovensForm-wound coil presses and curing ovensCoil insertion tools and hydraulic pressesDC armature winding machines and bar windersCommutator undercutting and turning equipmentArmature banding machinesLarge field coil winding equipmentGrowler testing equipment for armaturesEnsure proper calibration and maintenance of testing equipmentMaintain clean, organized, and safe work environmentIdentify needs for equipment upgrades or tooling improvementsSafety & Compliance:Enforce safety procedures specific to rewind operationsEnsure proper handling and disposal of varnish, solvents, and chemical materialsImplement safety protocols for DC machine work:Safe handling of heavy armatures and field framesProper rigging and lifting proceduresLead exposure control when working with older commutatorsSafe operation of high-temperature soldering equipmentProper ventilation during commutator workMonitor ventilation systems in varnish and oven areasRequire use of appropriate PPE (respirators, gloves, protective clothing)Conduct department safety meetings and toolbox talksInvestigate accidents and implement corrective actionsEnsure compliance with OSHA regulations and environmental requirementsDocumentation & CommunicationMaintain accurate winding records and test dataCreate detailed winding diagrams for future repairsDocument DC machine specifications:Armature winding data and connection diagramsField coil data and polarity diagramsCommutator bar counts and pitch informationBalancing specifications and resultsDocument non-standard repairs and special proceduresCommunicate job status and technical issues to Production ManagerInterface with customers on technical winding questionsReport daily production metrics and quality issuesRequirementsEducation & ExperienceHigh school diploma or equivalent; technical school training preferredMinimum 7-10 years of hands-on electric motor winding experienceAt least 5 years experience with DC armature and field rewindingDemonstrated experience with large DC machines (1000+ HP)At least 3-5 years in supervisory or lead positionComprehensive experience with both random wound and form-wound coils