Materials Operations Director

Position Summary:

The Materials Operations Director is responsible for leading and optimizing all aspects of material planning, warehouse operations, inventory control, production scheduling, and sales order fulfillment within a manufacturing environment.

This role drives operational excellence through lean material flow strategies, Kanban system design and management, and the development of efficient warehouse and inventory processes that support customer delivery, productivity, and cost objectives.

The ideal candidate is a strategic and hands-on leader with deep manufacturing experience, strong people leadership skills, and a proven ability to implement scalable materials and logistics systems that support operational growth and continuous improvement.

Key Responsibilities:

Lean Material Flow & Operational Excellence

• Lead the design, implementation, and continuous improvement of lean material flow strategies across manufacturing and warehouse operations.
• Eliminate waste and improve efficiency through value stream analysis, standardized work, visual management, and pull systems.
• Drive continuous improvement initiatives focused on productivity, inventory reduction, space utilization, and throughput.
• Partner cross-functionally with Operations, Engineering, Purchasing, and Production teams to optimize end-to-end material movement.

Warehouse Design & Inventory Management

• Direct warehouse layout design and optimization to improve material handling, storage density, workflow efficiency, and inventory accuracy.
• Develop and implement best practices for receiving, storage, picking, replenishment, and shipping operations.
• Ensure accurate inventory control processes and cycle counting programs are maintained.
• Evaluate and implement warehouse technologies, material handling equipment, and process improvements.

Plan for Every Part (PFEP)

• Develop, implement, and maintain a comprehensive Plan for Every Part (PFEP) system.
• Establish standardized material handling methods, replenishment strategies, container specifications, and inventory parameters for all parts.
• Utilize PFEP data to support lean manufacturing initiatives and improve material availability and flow.

Production Scheduling & Sales Order Fulfillment

• Oversee production scheduling activities to align manufacturing capacity with customer demand and operational priorities.
• Collaborate with Sales, Customer Service, and Operations teams to ensure timely and accurate sales order fulfillment.
• Monitor key performance indicators related to schedule attainment, on-time delivery, backlog management, and customer service levels.
• Drive improvements in planning accuracy, lead times, and inventory availability.

Kanban Design & Management

• Design, implement, and manage Kanban systems to support pull-based replenishment and lean manufacturing objectives.
• Establish Kanban sizing, replenishment triggers, and inventory management standards.
• Continuously monitor and optimize Kanban performance to improve responsiveness and reduce excess inventory.

Leadership & Team Development

• Lead, mentor, and develop materials, warehouse, planning, and scheduling teams.
• Foster a culture of accountability, collaboration, continuous improvement, and employee engagement.
• Establish clear performance expectations and support professional development initiatives.
• Ensure compliance with company policies, safety standards, and operational procedures.

Qualifications:

Required Qualifications

• Bachelor’s degree in Supply Chain Management, Operations Management, Industrial Engineering, Business, or related field.
• Minimum of 10 years of experience in a manufacturing environment with progressive leadership responsibilities.
• Proven experience in people management and team leadership.
• Strong knowledge of lean manufacturing principles and material flow strategies.
• Experience with warehouse design, inventory control, and logistics operations.
• Demonstrated expertise in PFEP development and implementation.
• Experience with production scheduling and sales order fulfillment processes.
• Hands-on experience designing and managing Kanban systems.
• Strong analytical, organizational, and problem-solving skills.
• Excellent communication and cross-functional collaboration abilities.

Preferred Qualifications

• Experience with ERP/MRP systems and warehouse management systems (WMS).
• Lean Manufacturing or Six Sigma certification preferred.
• Experience in high-mix, low-volume or complex manufacturing environments is a plus.
• Key Competencies
• Strategic Leadership
• Lean Thinking
• Operational Excellence
• Inventory Optimization
• Process Improvement
• Change Management
• Team Development
• Data-Driven Decision Making
• Customer Focus
• Cross-Functional Collaboration

Culture:

• Foster a collaborative and positive work environment, ensuring clear and respectful communication across all levels of the organization
• Actively drive change by encouraging and implementing cross-functional improvements that enhance operational efficiency and product quality
• Respectfully listen to concerns and ideas brought to your attention
• Respect confidentiality
• Embody our values of Integrity, Trust, Creativity and Courage, Teamwork, and Excellence

Working Conditions:

• Fast-paced manufacturing environment.
• Requires standing, walking, and lifting for extended periods.
• May involve exposure to noise and varying temperatures.
• Occasional lifting up to 50 lbs.

Attendance Requirements: Attendance on a regular, consistent basis is mandatory.

Accommodations: Essential functions of this position may include but are not limited to lifting, reaching, bending, stooping, twisting, kneeling, crouching, carrying objects, ascending/descending stairs and commuting to work location.

Pay Range: $125K - $145K with annual bonus