Senior Manager, Manufacturing Operations (M2)

About the role

The Senior Manager, Manufacturing Operations (M2) oversees the entire value stream within the plant. They are responsible for developing and managing the annual operational plan/playbook, improving key metrics such as safety, quality, delivery, and cost, and aligning area metrics with overall plant goals.

Responsibilities

• Own and prepare the annual operational plan/playbook for a manufacturing value stream.
• Manage and coach salaried and hourly team members to achieve high performance in areas of safety, quality, delivery, and cost.
• Head up activities of cross-functional manufacturing team, including responsibility for salaried and hourly team members within the assigned business unit.
• Utilize production line boards to collect information on value stream performance, issue identification, and problem resolution.
• Ensure information is passed on to the following shift and management.
• Hold team accountable to maintain and manage the boards.
• Maintain a good technical knowledge of operations; follow the escalation process to address and respond to abnormalities and recommend corrective action as required.
• Ensure the Lean manufacturing practices and Escalation Process set forth under the Appliance Production System are followed and adhered to within the value stream manufacturing operations.
• Manage and track all department metrics and budget. Prepare daily report-outs of metrics for production meetings.
• Establish daily operating rhythm in department. Conduct daily start-up meetings with Area Business Leaders.
• Prepare topics for daily team meetings; ensure team leaders understand and cascade the message appropriately and correctly. Rotate through the team meetings each day.
• Oversee the deployment of standardized work within the value stream operation. Ensure process stability through following standardized work.
• Coach and develop Area Business Leaders to ensure standardized work is in place and is followed.
• Ensure adherence to Job Instruction method by reviewing and verifying Job Instruction forms and including cross training matrix.
• Maintain 5S standards for the entire value stream.
• Livest, promote, and teach the Appliance Production System philosophy and steer continuous improvement within the value stream operation.
• Manage and promote work teams that react proactively to factory inefficiencies. Steer problem-solving and root cause identification of problems for the entire value stream.
• Engage all members of cross-functional escalation team to address and resolve problems, including Area Business Leaders, Team Leaders, Kaizen Promotion Officers, and other Lean resources.
• Continuously identify and work to reduce waste in the area for both short-term and long-term improvement initiatives.
• Serve as a second-level responder within the escalation process for problems/issues within the value stream operation.
• Run regular meetings to review department issues. Prioritize and assign ownership for open items. Track items to closure and ensure follow-up with key stakeholders.
• Promote kaizen events within the department. Ensure related countermeasures are implemented on manufacturing line(s).
• Oversee the planning and execution of work area rebalancing utilizing Yamazumi charts.
• Lead the creation of goals for each member of the team. Ensure career coaching, performance feedback, employee training, and talent development.
• Participate in the annual performance review process.
• Manage employee disciplinary investigations and actions as appropriate. Partner with HR to conduct timely investigations when necessary. Complete accurate and thorough disciplinary records with supporting documentation.
• Recruit resources to fill team needs in a timely fashion.
• Develop and mentor future leaders for the business.
• Partner with CoE Human Resources team to ensure fair and consistent administration of all policies, work rules, and processes.
• Ensure the products produced within the entire value stream operation are defect-free and produced according to specifications.
• Ensure Manufacturing Control Plan (MCP) and all quality processes/standards are followed within the entire value stream.
• Monitor manufacturing processes, data & reports daily and deliver resolution or escalation for any defect.
• Ensure Quality team members and PIE’s include quality standards in Standardized Work to meet design intent and build in quality.
• Work cross-functionally with multiple stakeholders to address and solve production line quality issues (i.e., engineering, quality).
• Monitor scrap data/reports to steer resolution of scrap issues and work projects to prevent future scrap.
• Partner with Plant Quality staff and engineering to deliver improvements in key quality metrics, including First Pass Yield, Overall Yield, and Service Call Rate (SCR) metrics.
• Responsible for the overall safety performance and metrics for the value stream operation.
• Promote a solid safety-minded culture in the value stream. Maintain an active safety program, ensuring the observation of safety precautions and safe work methods by all personnel, including behavior-based safety observations, safety meetings, safety audits, and 5S housekeeping standards.
• Enforce compliance to safety rules and procedures, timely accident investigations, Safety Contacts, and Safe Start participation.
• Review and sign off on all accident investigations. Ensure they are completed in a timely manner and identify root cause and corrective action to guide required changes.
• Manage the department's safety action item list, including corrective actions from near misses, accident reports, and ergo assessments.

Qualifications

• Bachelor’s degree or equivalent experience required.
• 7 years of leadership experience in a manufacturing environment, supplier management, and project implementation.
• Demonstrated accomplishments showing results-driven methodology, analytical methods, schedule achievement, teamwork.
• Demonstrated experience working with individuals at all levels of the organization to achieve operational results and positive union relations.