What are the responsibilities and job description for the Foundry Operations Manager position at Farrar Corporation?
Position Title: Foundry Operations Manager
Employment Type: Full-Time, Salary ExemptLocation: On-Site in Norwich, KS
Reports To: President/CEO
Supervise: Foundry Superintendent, Safety Supervisor, Maintenance Supervisor, and Production Control
Eligibility: Applicants must be legally authorized to work in the United States.
Position Summary:
The Foundry Operations Manager is responsible for overseeing all aspects of our green sand ductile iron foundry operations, including production, safety, foundry quality, foundry maintenance, Farrar scheduling, and workforce management. This role ensures efficient use of resources, compliance with environmental and safety regulations, and continuous improvement of processes to meet customer requirements and company goals.
- Operations Management
- Direct, coordinate, and oversee daily foundry operations across melt, core, mold, pour, shakeout, cleaning, and finishing departments.
- Monitor and improve upon key performance indicators (KPIs) such as scrap rates, efficiency, downtime, and on-time delivery.
- Safety & Compliance
- Promote and enforce a strong safety culture throughout the foundry.
- Ensure compliance with OSHA, EPA, and other applicable health, safety, and environmental regulations.
- Quality Assurance
- Work closely with the metallurgical and quality control teams to maintain product integrity.
- Drive foundry corrective actions for non-conforming products and implement process improvements to reduce scrap and rework.
- People Management
- Lead, mentor, and develop supervisors, leads, and hourly employees.
- Manage staffing, scheduling, and training to ensure a skilled and engaged workforce.
- Continuous Improvement
- Implement lean manufacturing principles, 5S, and other operational excellence initiatives.
- Identify opportunities to improve efficiency, reduce costs, and enhance production capability.
- Reporting & Budgeting
- Manage operating budgets, cost controls, and performance reports.
- Provide senior management with regular updates on operations performance and improvement initiatives.
- Bachelor’s degree in Operations Management, Industrial Engineering, or equivalent experience.
- 7 years of foundry or heavy-manufacturing leadership experience, with at least 3 years in a management role.
- Demonstrated ability to lead teams, manage production schedules, and drive process improvements.
- Excellent problem-solving, organizational, and communication skills.
- Proficiency with ERP systems, production planning tools, and Microsoft Office Suite.
- Strong knowledge of casting processes, melting operations, molding, and finishing practices is preferred.
- Strong commitment to safety and quality standards; preferably ISO 9001
- Frequent exposure to heat, dust, noise, and heavy industrial conditions.
- Ability to wear required PPE, including respirators, hearing protection, and safety glasses.
- Must be able to stand, walk, and lift up to 50 lbs. as needed.
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