Plant Operations Manager

About the role

The Plant Operations Manager oversees activities and resource allocation within the Assembly Line, directly managing supervisors and collaborating with cross-functional teams such as manufacturing engineering, fabrication departments, materials, logistics, purchasing, and design engineering teams.

Responsibilities

• Develop and meet Divisional, Site, and Value Stream goals through continuous improvement, waste reduction, and process optimization initiatives.
• Drive cultural and behavioral changes that support a Lean transformation journey to achieve sustainable success.
• Design and develop tools, controls, equipment, and processes required for the assembly line to produce final products of Johnson Controls Air Handling Units.
• Support continuous improvement activities on the shop floor using lean manufacturing tools.
• Coordinate activities and work with supervisory staff to achieve production metrics, including productivity and on-time delivery performance.
• Spend extensive time on the shop floor (Gemba) developing teams and managing performance to drive continuous improvement and eliminate waste.
• Apply Lean principles to implement new production methods, optimize layouts, and collaborate with Quality to establish standards and resolve manufacturing issues.
• Allocate and manage resources (manpower, equipment, and materials) to optimize production output with respect to delivery, quality, and cost.
• Lead teams in achieving goals in safety, quality, delivery, inventory, and productivity value stream daily goals, leading tier daily management boards/KPIs.
• Manage shifts by effectively utilizing supervisors and their resources.
• Coordinate activities of various departments and/or shifts to ensure that all areas are working on the appropriate tasks.
• Develop strategic operating, capital, and other plans to improve effectiveness of operation.
• Work with his/her team to develop and implement materials management strategy (make/buy, Kanban/MRP, inventory levels).
• Maintain effective working relationships and communication with all departments.
• Establish budgets and operating targets.
• Participate in Product Team meetings to help effectively improve the product line performance.
• Analyze operational performance and develop priorities/actions for improvements.
• Responsible for all aspects of shop floor management in assigned areas.
• Assure that safe work practices are followed.
• Aid in relevant Johnson Controls Business System action items/activities as pertains to your knowledge/skill set and technical ability.
• Responsible for driving Safety Performance in the area and in the plant.
• Ensure Safety Training is completed as required for Direct Reports.
• Map current value stream and develop future state vision with actions to implementation.
• Build strong relationships and collaborate with cross-functional teams including Safety, Operations, Maintenance, Quality, New Product Introduction, Advanced Manufacturing Engineering Team, Supplier Engineering, and Continuous improvement functions.
• Data Analysis: Collect and analyze data to identify areas of waste or inefficiency. Use data to optimize productivity, innovation, and supply management.
• Recruit, coach, and develop organizational talent fostering a diverse workplace that enables all participants to contribute to their full potential in pursuit of organizational objectives.
• Maintain compliance with company policies and procedures.
• Direct activities of manufacturing engineers in developing labor standards, work instructions, standard work, and labor costing.

Requirements

• Bachelor’s degree in engineering, Business Administration, or a related field or equivalent degree preferred.
• A minimum of 8 years’ manufacturing and production operations and/or manufacturing engineering experience, including at least 4 years’ successful supervisory/management experience.
• Strong background in Lean Manufacturing as well as other training in formal problem solving and operational analysis, such as Value Stream Mapping, 5S, Kanban, Standardized Work, Line Balancing/Yamazumi Charts, etc.
• Demonstrated track record of project management execution and a high-level of performance in current and previous positions.
• Must have hands-on experience in cost estimating and project management.
• Demonstrated ability to manage and prioritize multiple projects and initiatives, and experience leading large-scale Lean and Continuous Improvement initiatives with ability to work collaboratively and build strong relationships across all levels of the organization.
• Willingness to work additional hours and varied working hours to effectively manage people across all shifts.
• Proficiency in Microsoft Suite Applications (Office, Word, Excel, PowerPoint, Outlook, Teams, etc.).
• Experienced with MRP system is preferred.

Qualifications

• Must have a valid driver's license.
• Must be able to pass a drug test.
• Must be able to lift up to 50 pounds.
• Must be able to work flexible hours and weekends as needed.

Skills

• Lean Manufacturing
• Value Stream Mapping
• Kanban
• Standardized Work
• Line Balancing/Yamazumi Charts
• Cost Estimating
• Project Management
• Team Leadership
• Continuous Improvement
• Operational Analysis
• Microsoft Suite Applications
• MRP System

Benefits

• Competitive salary and bonus
• Paid vacation/holidays/sick time - 15 days of vacation first year
• Comprehensive benefits package including 401K, medical, dental, and vision care - Available day one
• Extensive product and on-the-job/cross-training opportunities with outstanding resources
• Encouraging and collaborative team environment
• Dedication to safety through our Zero Harm policy
• JCI Employee discount programs

Pay

Hiring Salary Range: $112,000 - $168,000 (Salary to be determined by the education, experience, knowledge, skills, and abilities of the applicant, internal equity, location, and alignment with market data.)

Schedule

Varies based on department needs and shift requirements.