Plant Manager

We are seeking a dynamic and energetic Plant Operations Manager to lead and optimize our manufacturing facility’s daily operations. The Plant Operations Manager is the senior leader responsible for overseeing all day-to-day operations at our Bethlehem manufacturing facility. This hands-on leadership role drives operational excellence in a fast-paced fabrication environment, ensuring efficiency, quality, safety, and profitability across the plant. Reporting directly to the Executive Vice President, you will lead production planning, resource management, and continuous improvement initiatives. By applying lean manufacturing principles, you will optimize workflows, reduce waste, and enhance overall performance. This position requires a strategic thinker with strong decision-making skills who can balance customer demands, budgetary goals, and operational priorities while fostering a culture of accountability and innovation.

Responsibilities:

Operations Planning and Daily Execution

• Monitor and optimize production in real time, adjusting schedules, priorities, and resources to ensure on-time delivery and meet customer commitments.
• Serve as the primary decision-maker for job prioritization and coordination, leveraging ERP and scheduling systems for maximum efficiency.
• Interact daily with the operations supervisors to quickly resolve issues such as rework equipment downtime, material delays, shipping schedules, absenteeism, and customer-driven demands.
• Develop and implement recovery plans for any orders at risk of late shipment; lead customer communications to present solutions and secure revised timelines.
• Maintain accurate inventory control in partnership with Materials Management, ensuring seamless raw material flow and timely product delivery.

Capacity, Staffing, and Resource Management

• Monitor and analyze plant capacity, workforce levels, inventory, and resource allocation; proactively recommend adjustments to maintain optimal efficiency.
• Review and approve all overtime requests to balance productivity with cost control.
• Collaborate with manufacturing engineering to identify and implement process improvements that enhance capacity, boost efficiency, and ensure consistent quality.
• Act as final decision-maker on allocation of Mechanical Engineering resources (detailing vs. approval drawings) and job prioritization.

Financial & ERP Ownership

• Prepare and manage budgets, track variances, downtime, waste, and key performance indicators (KPIs) through detailed reviews, reports, and dashboards; present operational results to senior leadership and justify capital investments with clear ROI analysis
• Generate and distribute quarterly revenue forecasts to support strategic planning.
• Approve critical manufacturing data, including Manufacturing Order Quantities (MOQ), Manufacturing Order Points (MOP), variance reports, and quarter-end WIP calculations.
• Provide accurate labor time estimates for special fabrication requests, sales quotes, and costing worksheets to ensure competitive pricing and profitability.
• Determine special pricing and delivery schedules for Flexicon subsidiaries’ orders to meet customer requirements.
• Serve as a key contributor to ERP implementation and optimization, ensuring seamless integration and data-driven decision-making across operations.

Performance Leadership

• Drive manufacturing operations to achieve cost-effective production while meeting strict targets for quality, output, OEE, and on-time delivery.
• Champion lean manufacturing initiatives, oversee capital project justification, and strengthen inventory control, safety culture, and cross-functional collaboration.
• Provide hands-on leadership and coaching to supervisors and operations teams, fostering accountability and a culture of quality assurance and continuous improvement.

Requirements:

• Bachelor’s degree in engineering, Operations Management, or related field.
• Minimum 7 years of progressive manufacturing operations leadership experience, including managing multiple functions in a fabrication or assembly environment; familiarity with logistics/distribution preferred
• Strong understanding of lean manufacturing, ERP systems (e.g., MS Dynamics), budgeting/forecasting, and business/financial principles.
• Working knowledge of organizational effectiveness, quality control, and safety regulations.
• Excellent leadership, communication, and problem-solving skills.
• Proficiency in data analysis, mechanical troubleshooting, and ERP integration for decision-making.
• Ability to lead teams, drive change, and thrive in a dynamic manufacturing setting.