Plant Operations Leader - Lean, Quality & P&L

Primary Function

The Plant Manager will lead and manage the operations of a USA Wood Door location. This position requires a strategic thinker with a proven track record in leading people and processes, ensuring quality standards, and driving operational excellence. The ideal candidate will possess strong continuous improvement leadership skills, a comprehensive understanding of manufacturing and assembly processes, and the ability to drive and sustain standard operating processes that align with the 1

USAWD System. The Plant Manager may have direct reports to include functional leaders in Production, Quality, EHS, and Materials. This position has approximately 3-6 direct reports and up to sixty indirect reports; and reports to the Vice President & General Manager of USA Wood Door.

Primary Function

The Plant Manager will lead and manage the operations of a USA Wood Door location. This position requires a strategic thinker with a proven track record in leading people and processes, ensuring quality standards, and driving operational excellence. The ideal candidate will possess strong continuous improvement leadership skills, a comprehensive understanding of manufacturing and assembly processes, and the ability to drive and sustain standard operating processes that align with the 1

USAWD System. The Plant Manager may have direct reports to include functional leaders in Production, Quality, EHS, and Materials. This position has approximately 3-6 direct reports and up to sixty indirect reports; and reports to the Vice President & General Manager of USA Wood Door.

Key Accountabilities

Production Efficiency (20%)

• Oversee daily manufacturing operations to meet and exceed production schedules, quality standards, and customer expectations.
• Deliver and sustain 98% or better On-Time and Complete (OTC) production orders.
• Drive Lean Manufacturing and Six Sigma initiatives to improve safety, reduce costs, shorten lead times, and enhance customer satisfaction.
• Monitor plant KPIs for labor utilization and labor efficiency and implement corrective actions to ensure consistent performance and operational excellence.
• Create and sustain a culture of accountability.

• Manage plant capacity and create proactive solutions to mitigate production bottlenecks.
• Communicate lead times weekly by product line with internal and external customers.
• Maintain a detailed understanding of plant capacity to manage direct headcount and adjust plant flow accordingly to ensure capacity equals or outpaces demand.
• Continuously evaluate plant flow, machinery utilization, and load levels by production cell for operational risk and process improvement.
• Maintain visual production schedule and capacity models that support a Manage-for-Daily-Improvement (MDI) process.

• Lead and develop teams with specific duties, plans, and goals for each team member and routine feedback.
• Construct and ensure adherence to Standard Operating Procedures.
• Utilize Voice of Customer and Voice of Employee feedback to enhance team performance.
• Provide support, mentorship, and career path coaching to team members.
• Cross train team members to ensure employee growth and flexible operations.

• Own the P&L responsibility for the plant; manage cost structure and drive productivity initiatives to offset inflation and support growth.
• Collaborate with Finance, Sales, and Marketing to align operational capabilities with business objectives.
• Evaluate capital investments and staffing decisions with sound financial acumen.
• Ensure continuous improvement plans that drive costs out of the business while maintaining safety and quality.

• Ensure 100% compliance with safety policies, environmental regulations, and company procedures.
• Establish and maintain standardized work processes across locations in alignment to the 1
  
  USAWD System.
• Maintain ownership of internal and external quality management for plant production.
• Foster a culture that encourages proactive Voice of Employee feedback on EHS improvement opportunities.

• Bachelor’s degree in management, business, supply chain, or related field required
• Six Sigma, Lean Manufacturing Training is preferred.

• Minimum of 8 years of operations leadership in a manufacturing environment
• Experience in CNC machining, woodworking, and/or metal working environments.
• Experience in a highly customer service-centric manufacturing business.
• Proven leadership in implementing lean manufacturing methodologies with quantifiable results.
• Strong analytical skills with the ability to communicate detailed planning.
• Strong communication, mentoring, and team-building skills with the ability to create a culture of accountability.
• Demonstrated ability to lead through change and prioritize in a dynamic environment.
• Financial acumen with prior plant P&L ownership.
• Advanced…