Plant Operations Manager

The Plant Operations Manager is responsible for managing the daily operations of the manufacturing facility to ensure that the company meets or exceeds customer and company expectations while maintaining a safe, efficient, and productive work environment. The Plant Operations Manager oversees plant personnel, production planning and scheduling, manufacturing performance, inventory management, maintenance, quality, and continuous improvement activities.

The position works closely with Sales and Inside Sales to ensure customer orders are accurately entered and managed, appropriate ship dates are established and communicated, inventory is properly allocated and maintained, and orders are produced, invoiced, and shipped accurately and on time.

• Manage all plant personnel, including staffing, hiring, training, performance, and accountability.
• Establish optimum staffing levels to support production requirements and labor budget goals.
• Direct daily production activities, ensuring production schedules are met efficiently, safely, and on time.
• Plan and manage production schedules based on customer demand, available capacity, raw material availability, inventory levels, and production priorities.
• Coordinate closely with Sales and Inside Sales on current and future orders to ensure sales orders are accurate, inventory is available, production requirements are understood, and customer ship dates are realistic and achievable.
• Ensure sales orders contain accurate product, quantity, pricing/order information, requested ship dates, and other information necessary for proper order fulfillment.
• Monitor order fulfillment from sales order through production, shipment, and invoicing, ensuring discrepancies are identified and resolved promptly and invoices are processed accurately.
• Monitor inventory availability and commitments to support customer orders while maintaining appropriate inventory levels and minimizing shortages, excess inventory, and obsolete material.
• Manage and maintain accurate inventory records through cycle counting, inventory reconciliation, inventory turns, and periodic physical stock counts.
• Take action on customer product complaints and coordinate appropriate corrective actions.
• Monitor Overall Equipment Effectiveness (OEE) and drive improvements in equipment availability, performance, quality, and productivity.
• Review scrap produced by line, identify root causes, and implement corrective actions.
• Review equipment availability for each production line by tracking individual components of no-run time, including preparation, setup, changeover, breakdowns, breaks, preventative maintenance, cleanup, and other downtime.
• Review daily achieved run rates against established goal rates.
• Promote and practice Lean Manufacturing and Continuous Process Improvement principles with a focus on waste elimination & productivity.
• Coordinate with Maintenance to ensure timely servicing of equipment, including PM compliance.
• Promote and manage cleanliness, organization, and 5S practices throughout the entire facility.
• Ensure compliance with OSHA, EPA, state and federal regulations, and company safety and environmental policies and procedures.
• Assist in the preparation and management of capital budgets.
• Manage annual factory expenses and monitor performance against approved operating budgets.

• Support the effective use of MRP/SYSPRO for production planning, material requirements, inventory management, and order fulfillment.
• Coordinate with Sales and Inside Sales to understand current and future customer requirements.
• Promote Continuous Process Improvements throughout manufacturing and order fulfillment operations.
• Manage inventory accuracy, cycle counting, stock take counts, and inventory…