Plant Operations Director

SUMMARY:

The Plant Operations Director is responsible for overseeing and improving the effectiveness and efficiency of all manufacturing and related operations. Development, implementation, verification, and maintenance of manufacturing processes, operating in a matrix organization. Will have all production, maintenance, EHS, shipping & receiving under their leadership. Will have complete P&L oversight over $110M in top line revenue with approx. 375 associates.

SPECIFIC RESPONSIBILITIES:

• Operational Leadership: The ideal candidate will be equally comfortable in collaborating with the company’s leadership team to set the overall direction of the operation along its lean journey as well as managing the day-to-day tactical needs of the operation alongside the broader operations team.
• Strategic Planning & Lean Implementation: Develop and implement long-term strategies for improving plant operations, incorporating Lean methodologies aimed at improving operational performance, reducing lead times, and minimizing waste. Lead the evolution of Standard Operating Procedures (SOPs) that incorporate Lean tools and techniques for sustained improvement.
• Team Management & Lean Culture: Manage and mentor a team of department heads and supervisors. Foster a culture of continuous improvement by encouraging Lean thinking, training staff on Lean methodologies, and leading Kaizen events to drive process changes.
• Safety & Compliance: Champion the plant's safety culture.
• Quality Control & Lean Integration: Work alongside the Quality and manufacturing to ensure industry leading quality performance levels. Work closely with the quality assurance team to monitor product quality, identify defects, and implement corrective actions.
• Inventory & Production Control: Oversee inventory levels and planning schedules to ensure the timely availability of materials and minimize downtime due to supply shortages. Implement Lean practices such as Just-In-Time (JIT) to optimize inventory management and reduce waste.
• Performance Reporting: Monitor key performance indicators (KPIs) and Provide regular reports to upper management, highlighting successes, challenges, and improvement initiatives.
• Customer Relations: Collaborate with sales, customer service, and other departments to ensure customer satisfaction through on-time delivery, product quality, and responsiveness to customer needs.

QUALIFICATIONS:

Bachelor's degree in Engineering, Manufacturing, Operations Management, or a related field. An MBA or advanced degree is a plus.

• Lean Certification: Certification in Lean Manufacturing, Six Sigma, or a similar process improvement methodology (e.g., Lean Six Sigma Black Belt or Green Belt) is a plus.
• Experience: At least 12 years of experience in manufacturing operations, with at least 5 years in a leadership role (e.g., Operations Manager, Plant Manager, etc.). Proven experience in implementing Lean manufacturing practices and driving process improvement.
• Technical Skills: Strong knowledge of Lean manufacturing tools and techniques (e.g., Value Stream Mapping, Kaizen, 5S, JIT, TPM, Poka-Yoke). Familiarity with ERP systems, production scheduling software, and other relevant technologies.
• Leadership Skills: Proven track record of leading and managing teams in a manufacturing environment. Strong decision-making abilities, excellent communication skills, and the ability to inspire and motivate staff.
• Problem-Solving Abilities: Strong analytical and problem-solving skills, with the ability to resolve complex operational issues quickly and efficiently using Lean problem-solving, and Root Cause Analysis.
• Financial Acumen: Experience in managing budgets, controlling costs, and driving profitability, with a focus on Lean cost-saving strategies.
• Soft Skills: Exceptional organizational skills, time management, and the ability to work in a fast-paced environment under pressure.