Manufacturing Start-up Project Manager (51268)

Position Summary

The Project Manager, Manufacturing Startup will lead the planning, execution, and successful launch of a new manufacturing facility producing mission-critical Data Center HVAC equipment. This role is responsible for managing all aspects of factory startup, including capital equipment installation, industrial engineering and assembly process development, production staffing, first article builds, customer qualification requirements, and operational readiness.

Key Responsibilities

• Factory Startup and Program Management
  Lead manufacturing startup activities from facility readiness through production launch.
  Develop and manage detailed project timelines, budgets, milestones, and risk mitigation plans.
  Capture and manage cross-functional teams to achieve startup objectives.
  Monitor project performance and communicate status to executive leadership.
  Establish key performance indicators (KPIs) for startup readiness and operational excellence.

• Capital Equipment Management
  Define manufacturing equipment requirements for Data Center HVAC product lines.
  Manage capital expenditure projects including: Assembly line equipment, Material handling systems, Production tooling, Test equipment, Automation systems, Facility infrastructure upgrades.
  Coordinate equipment specification, procurement, installation, commissioning, and acceptance testing.
  Ensure equipment readiness aligns with production launch schedules.
  Manage vendor relationships and equipment performance requirements.

• Industrial Engineering and Assembly Process Development
  Lead manufacturing process design and implementation.
  Develop: Assembly workflows, Manufacturing routing structures, Work instructions, Standard operating procedures (SOPs), Line balancing and takt time analysis, Conduct time studies and labor planning activities.
  Develop production layouts that optimize safety, quality, efficiency, and scalability.
  Implement Lean Manufacturing and Continuous Improvement methodologies.
  Establish material flow, inventory control, and point-of-use systems.

• Staffing and Workforce Planning
  Develop comprehensive manufacturing staffing plans based on production forecasts.
  Determine labor requirements by department including: Assembly, Engineering, Material handling, Production supervision, Test operations.
  Partner with Human Resources to recruit, onboard, and train manufacturing personnel.
  Support leadership development and operational readiness initiatives.
  Develop workforce ramp-up plans to support customer demand growth.

• First Article Build and Production Launch
  Lead first article manufacturing builds and validation activities.
  Ensure manufacturing processes are capable of meeting engineering and customer specifications.
  Coordinate: Prototype builds, Pilot production runs, Process validation, Capacity verification.
  Identify and resolve manufacturing readiness issues prior to production launch.
  Drive corrective actions to support smooth transition into full-rate production.

• Customer Quality and Compliance Requirements
  Serve as primary manufacturing representative for customer qualification and audit activities.
  Ensure compliance with customer-specific quality requirements and specifications.
  Lead development of: Quality Plans, Control Plans, Process Failure Mode and Effects Analysis (PFMEA), Inspection Procedures, First Article Inspection Reports (FAIR)
  Support customer acceptance testing and production approval processes.
  Drive root-cause analysis and corrective action implementation for quality issues.
  Ensure adherence to industry standards and regulatory requirements.

• Risk Management and Continuous Improvement
  Identify project risks related to production readiness, quality, supply chain, staffing, and equipment installation.
  Develop mitigation plans and contingency strategies.
  Lead continuous improvement initiatives focused on: Safety, Productivity, Quality, Cost reduction, On-time delivery, Support future production capacity expansion initiatives.

Required Qualifications

• Bachelor's degree in Engineering, Manufacturing Engineering, Industrial Engineering, Operations Management, or related field.
• 7+ years of manufacturing project management experience.
• 5+ years supporting factory startup, greenfield manufacturing, or major production launch initiatives.
• Experience with capital equipment implementation and manufacturing automation projects.
• Strong understanding of industrial engineering principles and assembly process development.
• Experience leading cross-functional teams in a fast-paced manufacturing environment.
• Proven knowledge of Lean Manufacturing and Continuous Improvement methodologies.
• Experience managing project schedules, budgets, and resource allocations.

Preferred Qualifications

• PMP (Project Management Professional) certification.
• Experience manufacturing HVAC, cooling systems, mechanical equipment, or data center infrastructure products.
• Six Sigma Green Belt or Black Belt certification.
• Experience with ERP/MRP systems.
• Knowledge of quality management systems including ISO 9001.
• Experience supporting customer audits and qualification programs.
• Familiarity with APQP, PFMEA, PPAP, and First Article Inspection processes.