Operations Manager; Foam

Build Your Career with Ashley Furniture - Where Innovation Meets Comfort

Who We Are:

At Ashley, inspiring the love of home is at the heart of everything we do. As the worlds largest manufacturer of home furnishings, were more than a business - were a family driven by innovation, competitiveness, and an unwavering commitment to excellence. We persevere through challenges, push beyond the status quo, and constantly seek better ways to deliver an exceptional customer experience. Our solutions-first mindset and dedication to growth are why Ashley remains #1 in our industry.

If youre ready to grow, youve come to the right place. With a true "Growth Mindset," Ashley Furniture invests in developing future leaders and helps every team member learn from the best in the business.

If you are a current Ashley employee: Please login to your UKG account and apply using the internal job board.

Summary:

The Manager of Foam Fabrication directs production activities for multiple departments, work centers, and processes on an assigned shift, leading the foam production operations that are critical to Ashleys furniture manufacturing excellence. This leadership role leads and mentors production Supervisors to achieve overall performance goals for production output, cost efficiency, quality standards, and safety compliance. The Operations Manager coordinates production activities through strategic planning with departmental Supervisors, Schedulers, HR Managers, and Quality Systems Trainers to ensure that manufacturing objectives are accomplished in a timely and cost-effective manner while optimizing foam production processes and product quality.

Responsibilities:

Production Leadership & Operations Management

• Direct production activities for multiple departments, work centers, and processes on an assigned shift to meet production targets and quality standards

• Lead the efforts to develop new processes and improve product quality by working with internal and external customers and suppliers

• Plan in a forward capacity by working with purchasing, production planning, and inventory control to achieve and maintain product flow to meet production and financial objectives

• Ensure that shift personnel adhere to the highest standards of shop floor organization, plant cleanliness, and 5S principles

• Monitor production schedules and adjust priorities to meet changing business needs and customer requirements

• Coordinate with other shift managers to ensure seamless 24/7 operations and effective handoffs

Budget & Resource Management

• Work to maintain budget for functional area including labor, materials, utilities, and overhead costs

• Monitor and control departmental costs while maintaining production and quality standards

• Identify cost reduction opportunities without compromising safety or quality

• Track and report on financial performance metrics and variances

• Optimize resource utilization to maximize efficiency and minimize waste

Team Leadership & Development

• Ensure adequate staffing to meet production needs through effective workforce planning and scheduling

• Make employment decisions and/or recommendations on hiring, improvement plans, transfers, promotions, corrective actions, terminations, pay adjustments, etc.

• Coordinate and manage the work of employees by directing members of the team to meet the areas goals and production objectives

• Audit regularly to ensure standard operating procedures are being adhered to and quality standards are maintained

• Manage employee performance and assist employees in making improvements to their performance through coaching, mentoring, and administering performance reviews

• Recommend, plan, and/or implement employee training and skill development activities to build organizational capability

• Audit, maintain, and ensure employee time-keeping and absentee records are accurate and comply with company policies

• Communicate company and departmental issues and goals through weekly team meetings, regular individual employee meetings, coaching, training, and company-offered learning opportunities

• Facilitate employee growth and development by identifying career paths and providing developmental opportunities

Safety & Compliance

• Ensure employees receive proper safety training, maintain a safe work environment, and perform safe work practices at all times

• Perform regular safety audits and address unsafe conditions or behaviors immediately

• Ensure compliance with OSHA regulations, environmental regulations, and chemical handling requirements

• Lead safety meetings and promote a culture of safety awareness throughout the foam fabrication operations

• Investigate incidents, implement corrective actions, and prevent recurrence

• Ensure proper use of personal protective equipment (PPE) including respirators and protective clothing

Quality & Process Improvement

• Lead continuous improvement initiatives using Lean Manufacturing and Continuous Quality Improvement principles

• Implement system improvement methods to enhance efficiency, reduce waste, and improve product quality

• Conduct capacity planning and optimize product flow to maximize throughput and minimize bottlenecks

• Monitor foam quality parameters including density, firmness, consistency, and dimensional accuracy

• Collaborate with Quality Assurance teams to resolve quality issues and implement corrective actions

• Participate in root cause analysis and problem-solving activities

Cross-Functional Collaboration

• Coordinate production activities through planning with departmental Supervisors, Schedulers, HR Managers, and Quality Systems Trainers

• Work closely with Engineering, Maintenance, Quality, and Supply Chain teams to support operational excellence

• Partner with suppliers on raw material quality, delivery, and technical support

• Collaborate with customers (internal and external) to understand requirements and improve product performance

Resource Optimization

• Manage resources to optimize equipment, facilities, employees, methods, and materials

• Ensure proper maintenance and calibration of foam pouring and fabrication equipment

• Monitor equipment performance and coordinate with Maintenance on preventive and corrective maintenance

• Implement best practices for foam production, cutting, and fabrication processes

Core Values Demonstration

• Demonstrate the Companys Core and Growth Values in the performance of all job functions

• Model expected behaviors and hold team accountable to company values and standards

Qualifications:

• Associates degree in Business, Chemical Engineering, Manufacturing Technology, or related field required (or equivalent work experience)

• Minimum 5 years of experience in foam pouring production leadership or related manufacturing area

• Proven supervisory or management experience with direct reports

• Management of resources to optimize equipment, facilities, employees, methods, and materials

• Strong understanding of Lean Manufacturing and Continuous Quality Improvement principles

• Experience with system improvement methods, capacity planning, and product flow optimization

• Knowledge of polyurethane foam chemistry and production processes

• Excellent leadership and team-building skills with ability to motivate and develop high-performing teams

• Strong analytical and problem-solving abilities with data-driven decision-making approach

• Excellent communication and interpersonal skills with ability to collaborate across all organizational levels

• Proficient in Microsoft Office Suite (Excel, Word, Outlook)

• Ability to work flexible hours including evenings, weekends, and holidays as operational needs require

• Physical ability to walk production floors, stand for extended periods, and work in manufacturing environment with chemical exposure

Additional Qualifications, Preferred:

• Bachelors degree in Chemical Engineering, Industrial Engineering, Operations Management, or related field

• 7+ years of foam manufacturing or chemical processing experience in furniture, bedding, or related industry

• Lean Six Sigma certification (Green Belt or Black Belt)

• Experience with ERP systems (SAP, Oracle, or similar platforms)

• Background in budgeting, financial analysis, and P&L management

• Knowledge of OSHA regulations, environmental compliance, and chemical safety management

• Experience with automated foam pouring systems and advanced manufacturing technologies

• Project management experience with capital improvement initiatives

• Understanding of quality management systems and statistical process control

• Advanced degree (MBA) or professional certification in operations or manufacturing management

Work Environment:

This position is located in an active industrial manufacturing and distribution center with moderate to high noise levels, temperature variations, and material handling equipment in operation. The role requires extended periods of standing or walking on concrete floors and the use of personal protective equipment (PPE) such as safety glasses, steel-toed boots, respirators, and protective clothing. The manufacturing facility includes exposure to chemical fumes from polyurethane processing and production noise in a fast-paced environment with time-sensitive and safety-sensitive operations.

Pay:

Competitive compensation based on experience

Benefits We Offer:

• Health, Dental, Vision, Employee Assistance Program

• Paid Time Off; increases with years of service

• Paid Vacation, Holidays, and Your Birthday off

• Generous Employee Discount on home furnishings

• Professional Development Opportunities

• Tuition Assistance

• Ashley Wellness Centers (location specific) and Medical Tourism

• Telehealth

• 401(k) and Profit Sharing

• Life Insurance

Our Core Values:

Honesty & Integrity: Acts with transparency, discretion, and ethical judgment. Trusted to handle sensitive information and provide accurate, unbiased insights.

Dirty Fingernail: Takes full accountability for outcomes, not just tasks. Inspects details, ensures data accuracy, and follows through to completion.

Continuous Improvement: Actively seeks better ways to improve templates, tools, and processes. Learns from prior initiatives and embeds lessons into standard work.

Growth & Results Focus: Understands how transformation initiatives drive growth, cost reduction, and profitability. Keeps work aligned to enterprise priorities.

Culture of Leadership: Leads through influence, reliability, and example. Builds trust across functions and supports leaders at every level.

Customer-Centric & Boundaryless: Works across silos for the greater good of the organization. Ensures outputs meet the needs of executives, initiative owners, and teams.

Operational Excellence: Demonstrates strong organizational discipline, attention to detail, and the ability to translate ambiguity into clear, executable tools.

Interested in learning more about Ashley Furnitures Community Engagement programs, Environmental Stewardship, or our Core Values, click the links below:

• Corporate Social Responsibility

• View Our Corporate Brochure

We are an Equal Opportunity Employer and provide a drug-free working environment. While Ashley appreciates the interest of all candidates, only those meeting specific position requirements may be contacted. This job description does not constitute a written or implied contract of employment. The company reserves the right to revise or change job duties and responsibilities as the need arises.

Notice to Search Firms: We are not seeking assistance or accepting unsolicited resumes from search firms. We will not pay any placement, referral or other fees to any search firms unless we have agreed otherwise in a valid, written agreement for the specific position posted and signed by an authorized representative of Ashley Furniture Industries.

Please note this position is not eligible for current or future employment sponsorship. Candidates must be legally authorized to work in the United States without the need for visa sponsorship now or at any time in the future.