Manager, Materials

Generac; Rockford (IL); On-site; USD 90,000 - 130,000; Full time

Job summary

Generac seeks a Manager of Materials to optimize the end-to-end material flow from receipt through line-side presentation to production, including pick/pack/ship processes for efficient manufacturing operations.

The role emphasizes safety, continuous improvement initiatives, waste elimination, and reducing forklift requirements, with a focus on improving delivery performance and material movement across production lines.

Qualifications

• Bachelor's degree or equivalent in Engineering, Business, or Supply Chain.
• 5 years of progressive Operations management experience in a manufacturing environment.
• Transformational leadership using lean principles and Plan For Every Part (PFEP).

Responsibilities

• Oversee material flow from receiving to line-side production and final packaging.
• Develop and manage PFEP database and day-to-day operations.
• Lead pull-based systems with Kanban, supermarkets, and 2-bin replenishment.
• Drive 5S, continuous improvement, and lean manufacturing initiatives.
• Act as SAP super user and coordinate with suppliers and customers on manufacturing issues.

Skills

Lean principles

Plan for Every Part

Team leadership

Materials flow optimization

Inventory management

Continuous improvement

5S

Cross-functional collaboration

Education

Bachelor's degree in Engineering, Business, or Supply Chain

Tools

SAP

ERP systems

Job description

The Manager, Materials is responsible for material flow from receiving/inspection to line side presentation for production including end-of-line pick, pack and ship. This position is responsible for driving a safety environment, significant continuous improvement initiatives, elimination of waste, efficiency improvements, reduction of fork lift requirements in material handling, cycle counting and timely transactional reporting. This role is also responsible for ongoing improvements in delivery performance (internal and external), and uninterrupted material movement for production lines with efficient use of labor resources.

Major Responsibilities

• Work with material handling team to ensure material flow from incoming receiving/inspection to line side presentation for production including end-of-line pick, pack & ship (incoming receiving/inspection, offsite raw warehousing storage & control) is ready for production.
• Created and managed a Plan for Every Part (PFEP) database utilized in day-to-day operations
• Demonstrated experience in the design and implementation of lean pull based systems
• Implemented and managed day to day operations using supermarkets, 2 bin Kanban’s, tugger routes, point of use delivery in a 5S environment
• Managed material flow involving Work in Process (WIP) markets with pull based replenishment linked to production scheduling processes of level scheduling (heijunka), change over optimization and runner/repeater/stranger replenishment
• Oversee inventory management and control, accuracy, and established inventory guidelines and procedures.
• Ensures efficient and accurate materials presentation to support production operations.
• Oversee process execution for excess and obsolete materials.
• Manage and optimize daily warehousing operations across multiple shifts including staging, cycle count, receiving, storage of materials, shipping of finished goods and in-direct materials.
• Mentor and guide project team members to deliver on the project/program requirements.
• Act as liaison or support collaborations with customers and suppliers on a day-to-day basis to resolve any product/program manufacturing quality issues.
• Actively lead or participate in Failure Mode Effect Analysis teams.
• Plan and lead refresher activities and forums for continual learning.
• Work with Corporate materials team on strategy and process implementation
• Lead Continuous Improvements events related to Making Material Flow
• Demonstrate personal flexibility in approach and ideas and respond positively and support changes in procedures, process, technology, responsibility and assignments.
• Accountable for defining resource needs and works within budget and staffing parameters to accomplish objectives for area of responsibility.
• Supervise material handling team, including forklift drivers and material supervisors. Interview, hire, train, coach and develop direct reports.
• Act as SAP Super user within functional area as assigned

Minimum Job Requirements

• Bachelor's degree in Engineering, Business, Supply Chain or equivalent experience
• 5 years of progressive Operations management experience in similar work environment.
• Transformational leadership using lean principles utilizing Plan For Every Part

Preferred Qualification

• Demonstrated understanding and application of lean manufacturing principles;
• Effective verbal and written communication skills;
• Ability to collaborate with multiple sites
• Ability to operate in high mix, low volume and high volume, low mix production environments;
• Successfully manage shifting deadlines and priorities in a fast paced environment;
• Solid quantitative skill set and the ability to analyze, think and communicate with well-supported data;
• Demonstrated understanding of financial measurements and goals
• Knowledge of Microsoft Office Suite and data analysis skills;
• Previous experience using SAP or equivalent ERP
• Experience in international logistics
• Transformational leadership using lean principles

Physical Requirements And Working Conditions

While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders. The employee must occasionally lift up to 25 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Occasional travel. (If travel percentage is required beyond occasional or is a regular part of the job, include “Up to x% travel and valid Driver’s License required.”)

Production Environment

While performing the duties of this job, the employee is regularly required to stand. The employee is frequently required to use hands to manipulate objects, tools, or controls; and to talk and hear. The employee is regularly required to walk, stoop, crouch, bend and reach above shoulders. The employee must frequently lift and/or move up to 50 pounds unassisted and up to 100 pounds with assistance, waist high, up to 10 feet away. This job's specific vision abilities include close vision, distance vision, peripheral vision, and depth perception. While performing the duties of this job, the employee will be working in the typical conditions of a manufacturing environment, including seasonal variations in temperatures and occasional exposure to manufacturing fumes or byproducts. The employee must comply with the assigned location PPE requirements, including but not limited to safety glasses, hearing protection, appropriate gloves, clothing, and shields for required tasks, and closed-toed or safety shoes as required by facility safety policies. The employee must be able to work in varying weather conditions including extreme heat, snow, and ice. The employee may be required to obtain a DOT Medical Card and have the ability to drive a heavy-duty truck on a daily basis.