Injection Molding Operations Manager

Position: Injection Molding Operations / Facilities Manager

Job Summary: We are seeking an experienced Injection Molding Operations / Facilities Manager to oversee custom and proprietary injection molding operations and all equipment and facility related maintenance activities plantwide.

Key Responsibilities:

• Ensure planned objectives are met or exceeded (i.e. OEE, OTD, SMED, SPC and Lean 6s)
• Provide leadership by creating an environment of highly engaged and accountable employees focused on continuous improvement and customer satisfaction
• Collaborate on and adhere to the departmental budget
• Identify, investigate and implement capital expenditures including corresponding ROI
• Coordinate the activities of department supervisors, engineers, technicians, and support personnel to meet manufacturing objectives
• Maintain production standards, scrap rates, cycle times and minimize machine downtime to achieve OEE rates greater than 45%
• Maintain accountability for system processes and policies and take corrective action when necessary
• Improve departmental set-up/start-up and color change processes
• Raise the level of awareness by conducting regular meetings with peers, staff and/or employees regarding issues such as safety, quality, housekeeping, production, and other information as required
• Interact with other manufacturing departments, Product Quality, Materials, Engineering and Account Management to ensure customer satisfaction
• Identify training needs and coordinate training and development objectives for manufacturing personnel
• Develop systems and processes that track and optimize productivity and standards, metrics, and performance targets to ensure effective return on assets
• Work with and develop interdepartmental relations and strategies to ensure overall plant safety and organization
• Ensure training matrix is maintained and yearly training takes place in a timely manner
• Set achievable production goals and follow through with weekly supervisor meetings
• Resolve employee disputes and enforce all company policies and procedures
• HA, EPA and EHS guidelines
• Resolve manufacturing and maintenance issues to ensure minimum cost, maximum efficiency, and the prevention of operational delays
• Maintain a safe, clean, and orderly workplace in compliance with all regulations including applicable local, state, and federal laws
• Reviews standard operating procedures and revises as needed
• Ensure conformity to quality standards and has the authority to stop production to make corrections when necessary
• Develop a team culture and an environment for accountability and continuous improvement
• Coordinates and communicates staffing needs with Human Resources
• Be highly visible on the manufacturing floor
• Maintain electrical, hydraulic, water, air, and mechanical functions of all major and auxiliary equipment as well as the overall working condition of the facility
• Submit requisitions for tools and supplies used in maintenance activities
• Maintain equipment records using IQMS MRO
• Contact salesmen, suppliers, and servicemen through any type of communication necessary
• Initiate a safety check program based on the manufacturer's recommendations for all machinery and equipment
• Initiate and maintain a rigid preventive maintenance program on all equipment and building functions based on the manufacturer's recommendations
• Determine and maintain a sufficient inventory of spare parts to ensure minimum interruption to machinery and plant operation
• Attend monthly safety & housekeeping meetings
• Responsible for all internal and external building maintenance
• Oversee employees in the Maintenance Department
• Plan, assign, and direct work; appraise performance; reward and discipline employees; address complaints and resolve problems
• Oversee, plan and issue work orders to appropriate shift team members for the implementation of equipment modifications as well as preventative and any corrective maintenance
• Prepare and coordinate maintenance resources and provide recommendations for capital and continuous improvement projects
• Reviews the operation of equipment with appropriate personnel to identify maintenance issues in the areas of Safety, Quality, Cost, Productivity and Customer Satisfaction
• Makes recommendations for improving plant operations, OEE (Overall Equipment Effectiveness) and maintenance problem resolution
• Tracks, analyzes, and improves the Maintenance department's KPIs
• Fosters a positive and accountable working environment and drives Maintenance team to set/meet productivity targets and performance standards
• Ensures all regulatory compliance with various governmental agencies such as city, county, state is met on a consistent basis
• Monitors and reviews Maintenance budget monthly; Prepares and implements annual budget each fiscal year
• Maintains necessary permits and relationships with regulatory agencies and outside utility providers
• Utilizes facility maintenance resources and outside contractors to maintain equipment, plant utilities, prioritizing mechanical and electrical work
• Responsible for maintenance planning and spare parts strategy within the department
• Provides project leadership and support for facility related projects, including capital project development and execution
• Supports plant sustainability efforts in landfill diversion, water conservation and greenhouse gas footprint reduction
• Owner of technical documentation for facilities
• Maintains and tests the plant's fire control systems and lifting systems
• Serves as the primary contact for the plant's insurance provider
• Team member of Environmental Health & Safety (EHS)
• Manages plant maintenance, building grounds, and utilities budget
• Perform all other duties necessitated by changing business conditions

Requirements:

• BS in Plastics/Polymer/Mechanical or Industrial Engineering discipline, business/manufacturing or related field or the equivalent in similar plastics manufacturing experience
• Minimum six (6) to eight (8) years of plastic injection molding and maintenance experience in either a high volume or high-mix / high-complexity environment requiring various levels of automation, scientific molding, and secondary processes
• Proven leader which can build ownership across all areas of the department; assess talent and provide opportunities for increased responsibilities / advancement
• Understanding of Standard Cost, P & L, and variance reporting
• Must be able to understand blueprints, hydraulic schematics, and wiring diagrams
• Poses a working knowledge of heating, electricity 110, 240, 480-volt AC systems, 24-volt DC systems and other related machine componentry such as cartridge valves, variable displacement pumps, servo drives, etc.
• Familiar with preventative maintenance activities connected to air compressors, vacuum pumps, electric motors, hydraulic pumps, tower water systems, and electric ovens
• Understanding of ISO, GMP, OSHA and EPA regulations required
• Working knowledge of lean, six sigma, kaizen, scientific molding, SPC, SMED and other continuous improvement initiatives
• The ability to communicate effectively, both orally and in writing, and have excellent people skills
• Ability to exercise independent judgement and discretion in selecting methods, techniques, and evaluation criteria for obtaining results
• Must be willing to maintain the technological competency necessary to develop and manage a world class manufacturing facility
• Possesses the analytical and problem-solving skills necessary to perform the job
• Must be proficient in Microsoft Office Suite (i.e. Word, Excel, and PowerPoint) and working knowledge of an ERP database (IQMS experience a plus)

Physical Exertion: Capable of lifting 25 pounds or less. Works within a manufacturing environment around heavy machinery with temperatures fluctuating between 60 -100 °F. Mobility is required to move safely in and around each area of the facility.

Attendance: Must be in attendance on a regular, full-time basis with the ability to be present on each of three working shifts, spanning a 24-hr operation as needed. Must be willing and available to work more than 40 hours a week, including weekends when necessary.

Travel: Able to travel outside the country for short periods as necessary. Travel both domestic and international typically less than 5% of the time.

Status: Full-time salary exempt. This is an "at will" position.

Equal Employment Opportunity: All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability, or veteran's status.

Accommodation: Applicants with a disability or a disabled veteran may request a reasonable accommodation if he/she is unable or limited in his/her ability to access job openings or apply for a job on our website as a result of his/her disability. The applicant may request reasonable accommodations by contacting us at 317-661-1740.