Director of Forge Manufacturing Operations

About the role

The Director of Forge Operations is responsible for leading, strategizing, and overseeing all day-to-day and long-term manufacturing operations within the forge facility to ensure safe, efficient, and cost-effective production of high-quality products. This executive role provides leadership and strategic direction across multiple manufacturing departments, including steel forging, precision machining, heat treatment, and primary support functions. The Director of Forge Operations drives operational excellence through continuous improvement, talent development, strategic production planning, quality assurance, and strict adherence to safety and regulatory standards. The ideal candidate is an executive leader with extensive operational experience in heavy manufacturing environments and a deep background in forging, machining, and heat treatment operations.

Responsibilities

• Operational Leadership: Direct and coordinate plant-wide manufacturing activities across all forge operations to meet production schedules, quality standards, and customer requirements. Oversee multi-departmental operations, including: Closed-die forging press lines, Mechanical and hydraulic press operations, Machining and finishing departments, Heat treatment furnaces and operations, Material handling and workflow orchestration, Secondary processing and finishing. Monitor production metrics and implement strategic corrective actions to improve plant efficiency, throughput, and equipment utilization. Ensure effective cross-departmental alignment and communication to maximize productivity and eliminate operational bottlenecks. Establish facility goals and Key Performance Indicators (KPIs) related to safety, quality, productivity, delivery, and operational cost.
• Safety and Environmental Compliance: Champion an uncompromising culture of safety and environmental stewardship throughout the facility. Ensure full compliance with OSHA regulations, local environmental standards, and internal safety policies. Oversee routine safety audits, risk assessments, and incident investigations. Lead root-cause analysis and preventive action programs (CAPA) to eliminate workplace hazards and minimize risk. Ensure comprehensive safety training and certification programs are maintained across all operational levels.
• Quality Management: Partner with Quality Leadership to ensure all products meet or exceed customer specifications and industry quality standards. Investigate non-conformances and implement permanent corrective actions to prevent recurrence. Drive root-cause analysis and continuous improvement initiatives targeting scrap and rework reduction. Ensure strict process controls, testing protocols, and inspection procedures are maintained across all shifts.
• Employee Leadership and Development: Lead, coach, mentor, and build high-performing teams, including department managers, supervisors, engineers, and hourly personnel. Foster a culture of accountability, engagement,