Operations Manager

Responsibilities as they relate to current and new projects include establishing capital needs, launch strategy, project timing, employee involvement, customer representation and cross-functional communications and alignment relating to the projects.

• Lead by example to build and maintain a plant culture that embraces the values of CODE – Collaboration, Openness, Drive, and Empowerment.
• Challenge traditional boundaries and eliminate barriers which do not promote continuous improvement of the enterprise.
• Support and ensure safety policies and procedures are consistently followed throughout the facility.
• Lead, support, an develop the Production Supervisors, Technical Supervisor, and Process Technicians.
• Establish and track Production Department objectives/KPIs.
• Support root cause analysis and proper resolution to conflict.
• Report out KPIs, challenges, and planned corrective action implementations to various levels of leadership.
• Assess/evaluate team members to ensure continuous development and opportunities for internal growth/succession planning.
• Approval of production related expenses.
• Assist in establishing and monitoring key operating objectives of the production facility.
• Participate in future planning and proactively lead/support continuous improvement projects.
• Actively work with and effectively communicate to floor personnel to ensure quality product.
• Issue process improvements and cost reductions as required.
• Maintain appropriate manning and schedules to support customer requirements.
• Understand and facilitate continuous improvement of Quality and Environmental Systems (TS16949 and ISO 14000).
• Participate as a member of the plant Management QOS review team.
• Along with the total plant management team, develop and maintain healthy community relations.
• Act with a high sense of urgency, in particular with respect to customer needs.
• Assure that quality product is maintained along with production schedules being met.
• Set stretch goals/targets for direct reports and achieve them through rigorous use of continuous improvement and employee involvement methods.
• Manage budgets to drive the appropriate actions to adapt plant resources and costs to volume variation and launch readiness for new programs.
• Develop and follow production plans, as well as Grammer standard processes; ensure feasibility of production plans.
• Achieve financial targets: prepare and present the Operations budget; manage the actual production costs based on target costs; maintain product margin, and monitor serial productivity (labor level, material consumption, etc.).
• Manage the Operations teams: ensure appropriate staffing, maintain working environment according to Grammer
• Environment, Health, & Safety (EHS) standards, detect and advise training needs, share information (transparency), participate in people development initiatives.
• Meet established customer specifications concerning cycle time, delivery, quality, quantity and costs; implement preventative and corrective measures in the production process to ensure that customer demands are properly met; coordinate with Quality team to meet all customer standards.
• Implement action plans to improve functionality/productivity and to obtain program and Grammer objectives; make necessary corrective adjustments.
• Coordinate resource planning concerning inventory, equipment, staffing, activities, etc.
• Maintain dashboard indicators/status reports to monitor lead time, supply-chain targets, EHS, performance, etc.
• On the Job Training (OJT) of peers and Stop Scrap procedures.
• Develop proactive interrelationships between the plant supervisors and other functional support departments.
• Responsible for maintaining morale and employee relations in the plant
• Facilitate the Development of the operating budget and the capital budget
• Know and apply GPS ( Grammer Production Systems) Principles.
• Lead by Example; Be Respectful, Be Prompt, Be Consistent, Be Available
  
• Environment, Health, and Safety (EHS)
•  Responsible for the application of safety standards and for adhering to TS16949, ISO 14001 and 45000 standards using GPQ(Grammer Produces Quality) methodology (All functions)
• Ensure the plant functions according to the Control Plans, the established policies and procedures and adheres to all safety, environmental, and quality standards.
•  Responsible for resolution of all safety related issues in a timely manner within the area
• Monitor safety performance of the department and make improvements as required.
• Ensure workforce has completed all safety related training requirements
• Perform safety observation tours at scheduled intervals.
• Maintain excellent housekeeping in your areas at all times.
•  Comply with all safety and environmental regulations
• Quality
•  Ensure ALL Quality Gates/Quality Inspections/Error Proofing/FTQ Checks have been executed per the Process Control Plan every shift, every day.
• Perform daily layered process audits, address findings immediately.
• Approve all the Operator work instructions and work instruction revisions.
• Investigate, communicate, and resolve quality issues promptly.
• Use alarm and escalation process as defined
• Implement containment activities in a timely manner.
• Responsible for quality performance of the production lines as measured by KPIs on a daily basis.
• Use KPI charts to document activity.
• Perform scrap reviews on a daily basis and communicate/escalate issues.
• Use KPI charts to document activity.
  Execute Quality System Requirements, both Customer and Grammer GPQ system
• Products/Volume/Effective planning and scheduling (man, machine and material) of production area to meet production plan.
• Monitor hourly and daily throughput to ensure production plan adherence according to MPS and Production Plans
• Effectively communicate and work with all departments (maintenance, engineering, HR, quality, logistics and IT) to resolve issues in a timely manner.
• Responsible for the proper training and certification of all operators, BCI, and inspectors supporting the production are
•  Maintain Production plan adherence, productivity, performance data on visual boards
   Gemba walks
  
  Cost
•  Approve and execute engineering and process change introduction into production
• Identify and implement cost reduction ideas/Support Cost Reduction Roadmap
• Lead kaizen workshop events, execute improvements identified
• Achieve Mfg. KPIs for Safety, Quality, Volume, Cost, Scrap, Productivity
• Understand, Track, and Meet Budget Commitments
• Align resources amongst Business Units to meet Plant Priorities
• Communication/Environment/Drive an atmosphere of trust, respect and accountability.
• Train, coach, inspire, and engage Supervisors/Shift Leaders/Team Leaders
• Effectively resolve and communicate issues to the team.
• Effectively communicate and work with all department (maintenance, engineering, HR, quality, and IT) to resolve issues in a timely manner.

• Bachelors Degree in a related field of study
• A minimum of 5 years experience in a similar role and a minimum of 10 years experience in the Automotive industry or a similar large-scale manufacturing environment
• Automotive industry experience
• Plant start-up or high product launch exposure a plus
• Plastics experience preferred
• Greenfield / Brownfield launch experience is a plus.
• Proven experience in production management and lean manufacturing / production systems/ Toyota production system
• Proven experience in team management with leadership and coaching skills
• Ability to build and manage a P&L budget. Knowledge in Finance.
• Highly reciprocal with strong consultative, analytical, time management, and project management skills with the ability to
• influence, resolve complex problems, and identify systemic issues.
• Excellent communication and influencing skills. Experience handling difficult situations effectively, negotiates persuasively, ability to communicate information and convey ideas clearly. Initiates and develops important relationships based on trust and credibility.
• Ability to independently drive innovation and foster the development of new ideas/approaches/methods.