Senior Manager, Manufacturing Operations (M2)

MANUFACTURING OPERATIONS

Oversees manufacturing operations for an entire value stream within a plant.
Owns and prepares the annual operational plan/playbook for a manufacturing value stream.
Responsible for operational performance and improvement of key metrics including safety, quality, delivery, cost and culture.
Aligns area metrics with overall plant goals; organizes resources to deliver on these metrics.
Leads activities of the cross-functional manufacturing team, to include responsibility for salaried and hourly team members within the assigned business unit.

• Direct Reports include Area Leader (AL), Team Leaders (TL) and Indirect: Team Members.
• Maintain a good technical knowledge of operations; follow the escalation process to address and respond to abnormalities and recommend corrective action as required.
• 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 rigor around daily team leader meetings, escalation meetings, etc.
• 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 Leaders and Team Leaders to ensure standardized work is in place and is followed.
• Ensure adherence to Job Instruction method by reviewing and verifying Job Instruction forms, including cross training matrix, and Team Leader delivery of four step method to ensure ‘Critical Points’ and ‘Why’ are conveyed accurately and effectively.
• Ensure 5S standards are met for the entire value stream.

CONTINUOUS IMPROVEMENT

Live, promote and teach the Appliance Production System philosophy and drive continuous improvement within the value stream operation.
Lead and promote work teams that react aggressively to factory inefficiencies.
Drive 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, ex. Area Leaders, Team Leaders, Kaizen Promotion Office 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.
Lead regular meetings to review department issues. Prioritize and assign ownership for open items. Track items to closure and ensure follow-up with key stakeholders.
Champion kaizen events within department. Ensure related countermeasures are implemented on manufacturing line(s).

• Oversee the planning and execution of work area re-balancing utilizing Yamazumi charts.

LEADERSHIP

Provide active day-to-day leadership for a highly energized, integrated, cross-functional manufacturing team.
Create goals for each member of the team.
Ensure individual career coaching, performance feedback, employee training and talent development.
Participate in the annual performance review process.
Lead employee disciplinary investigation and action 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 site Human Resources team to ensure fair and consistent administration of all policies, work rules and processes.

QUALITY

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 entire value stream.
Monitor manufacturing processes, data & reports on a daily basis and drive the resolution or escalation for any defect.
Ensure Team Leaders 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. Team Leader, engineering, quality).
Monitor scrap data/reports to drive resolution of scrap issues and work projects to prevent future scrap.
Partner with Plant Quality staff and engineering to drive improvements in key quality metrics, including First Pass Yield, Overall Yield and Service Call Rate (SCR) metrics.

Safety

Responsible for the overall safety performance and metrics for the value stream operation.
Promote a strong 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 with 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 drive required changes.
Manage the department's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.