Plant Manager

Summary/Objective:

The Plant Manager - MEI is responsible for leading all aspects of production, personnel supervision, and process performance within the operation of Plant 3 wrap manufacturing value stream. This role ensures safe, compliant, and efficient operations while driving continuous improvement, maintaining IATF 16949 and ISO 14001 standards, and achieving Safety, Quality, Delivery, and Cost (SQDC) targets. The Value Stream Manager oversees staffing, training, workflow optimization, and cross-functional collaboration to consistently meet customer requirements, reduce waste, and strengthen operational excellence across the facility.

Essential Functions:

1. Leadership & Personnel Supervision

• Provide daily leadership, coaching, and direction to all employees within the value stream.
• Oversee staffing, scheduling, capability development, and cross-training of production teams.
• Conduct performance evaluations, corrective actions, and employee development plans.
• Maintain a positive, safe, and accountable work environment.
• Ensure adherence to all company policies, standard work, and safety procedures.
• Support onboarding and training of new personnel in processes, safety, and quality requirements.

2. Production Planning & Execution

• Manage day-to-day production operations to meet SQDC goals (Safety, Quality, Delivery, Cost).
• Ensure daily attainment of production schedules, takt time, and customer requirements.
• Coordinate with Planning, Purchasing, Engineering, and Quality to optimize production flow.
• Monitor run rates, downtime, scrap, and throughput; implement adjustments as needed.
• Lead daily Gemba walks, tier meetings, and value stream huddles.

3. Process Ownership & Improvement

• Own all processes within the assigned value stream, including wrap lines, metal encapsulation, material handling, curing, and finishing.
• Implement and maintain standardized work, visual controls, and error-proofing.
• Drive continuous improvement through Lean tools: 5S, Kaizen, VSM, SMED, Kanban, TPM, Poka-Yoke.
• Lead cost reduction initiatives, efficiency improvements, and material yield optimization.
• Analyze bottlenecks and implement engineered solutions in coordination with Maintenance/Engineering.

4. Safety, Environmental & Compliance Responsibilities

• Ensure all personnel follow OSHA and facility safety policies (PPE, LOTO, machine guarding, chemical handling).
• Conduct and document safety walks, incident investigations, and corrective actions.
• Support ISO 14001 and environmental compliance—waste management, emissions, hazardous materials control.
• Maintain 5S in all production areas and ensure proper ergonomics and workstation design.

5. Quality & Customer Requirements

• Ensure all operations comply with IATF 16949 and ISO 14001 requirements.
• Maintain quality control plans, inspection standards, and traceability requirements.
• Collaborate with Quality to quickly address nonconformances, CAPAs, SCARs, deviations, and customer complaints.
• Verify first-piece approvals, in-process inspections, and final audits meet specification.
• Monitor key quality metrics including scrap, rework, dimensional accuracy, metal wrap integrity, and bonding performance.

6. Cross-Functional Collaboration

• Partner with Engineering on new product introductions, process changes, and material qualifications.
• Work closely with Maintenance to minimize downtime, schedule PMs, and escalate critical equipment issues.
• Collaborate with Supply Chain on material flow, vendor performance, and inventory accuracy.
• Serve as the primary communication link between production, management, and supporting departments.

7. Data Management & Performance Reporting

• Track and report KPIs: OEE, scrap, throughput, labor efficiency, safety, and customer delivery performance.
• Review daily production reports and use data to drive structured problem solving (5 Why, Fishbone, A3).
• Maintain visibility boards and ensure accurate data entry in ERP/MES systems.
• Prepare weekly and monthly performance summaries for leadership.

8. Budget, Cost & Resource Management

• Manage labor allocation, overtime approval, and cost control for the value stream.
• Identify cost-saving opportunities through process optimization and waste elimination.
• Support capital equipment justification and ROI analysis.
• Optimize material usage, including metals, adhesives, films, insulation, and wrap components.

9. Change Management & New Product Integration

• Lead controlled rollout of process changes, revisions, and engineering updates.
• Ensure employees are trained and competent in new methods before implementation.
• Support APQP activities including PFMEA, control plans, work instructions, and PPAP submissions.
• Coordinate trials, capability studies, and validation runs for new or modified products.

10. Culture Development

• Promote a culture of safety, quality, teamwork, and accountability.
• Encourage employee engagement, problem-solving, and ownership of improvement ideas.
• Support open communication and foster trust within the value stream.
• Demonstrate leadership that aligns with facility values and customer expectations

You should be proficient in:

• Continuous Improvement
• 5 Why (Root Cause Analysis Method)
• Advanced Product Quality Planning (APQP)
• Lean Manufacturing Principles
• Operational Metrics & KPI Management
• Production Planning & Scheduling
• PPAP Process Experience
• ISO 14001 Certification Experience