This highly visible plant leadership role will champion the organization's Continuous Improvement System (ECIS), Business System (EBS), Lean Manufacturing, and Six Sigma methodologies to build a strong culture of problem solving, operational discipline, and sustainable performance improvement. The OPEX Manager will work directly with the plant leadership team to develop and execute the site's continuous improvement roadmap, strengthen daily management systems, develop employee capabilities, and accelerate business results across manufacturing operations. This position is ideal for a hands-on continuous improvement leader who can translate business strategy into practical improvement initiatives, coach employees and leaders, and deliver sustainable operational and financial results.
Key Responsibilities:
1. Operational Excellence Strategy & Deployment
- Champion ECIS, EBS, Lean, and Six Sigma methodologies across the manufacturing facility.
- Partner with plant leadership to develop, deploy, and sustain the site's continuous improvement strategy.
- Establish governance processes and annual improvement priorities.
- Translate business objectives into practical operational improvement initiatives.
- Drive short- and long-term improvements in safety, quality, delivery, cost, productivity, working capital, and customer satisfaction.
- Serve as the site expert and champion for the organization's Business System.
- Connect business priorities with daily operating routines and improvement activities.
2. Lean Manufacturing & Continuous Improvement
- Lead Lean and Six Sigma initiatives to eliminate waste, improve process flow, reduce variation, and strengthen operational performance.
- Apply Lean tools and methodologies, including: Value Stream Mapping (VSM), 5S and workplace organization, Continuous Flow Manufacturing, Setup Reduction, Total Productive Maintenance (TPM), Error Proofing / Poka-Yoke, Pull Systems, Standardized Work, Kaizen, Rapid Improvement Events (RIE)
- Identify opportunities to improve manufacturing efficiency, productivity, quality, and equipment performance.
- Lead cost-out and productivity improvement projects to achieve annual savings commitments.
- Establish sustainable improvement practices to maintain results over time.
3. Daily Management & Operational Discipline
- Build a culture of structured problem solving and accountability.
- Implement and strengthen leader standard work.
- Establish daily accountability routines, visual management systems, and process checks.
- Conduct Gemba walks to identify operational gaps and improvement opportunities.
- Drive disciplined follow-up on corrective actions and improvement commitments.
- Strengthen operating routines across manufacturing and functional departments.
- Coach leaders on connecting daily operational activities with broader business objectives.
4. Operational Assessment & Performance Management
- Lead Operational Assessment (OpA) preparation, execution, and follow-up.
- Identify organizational and operational gaps through structured assessments.
- Develop action plans to address identified gaps and sustain progress.
- Analyze operational metrics and performance indicators to identify improvement opportunities.
- Recommend data-driven action plans to improve performance.
- Monitor implementation and strengthen accountability at the operating level.
5. Six Sigma & Structured Problem Solving
- Lead and support Six Sigma improvement projects across manufacturing and functional operations.
- Apply structured problem‑solving methodologies, including 8D and statistical analysis.
- Identify root causes, validate corrective solutions, and prevent recurrence.
- Reduce process variation and improve process capability.
- Use data and analytical methods to measure improvement effectiveness.
- Facilitate Kaizen events, Rapid Improvement Events, and cross‑functional problem‑solving workshops.
- Establish sustainable corrective and preventive action processes.
6. Leadership, Coaching & Employee Development
- Coach, train, and mentor employees and leaders on Lean, Six Sigma, and operational excellence principles.
- Develop continuous improvement capabilities across the organization.
- Lead cross‑functional improvement teams and facilitate collaborative problem‑solving activities.
- Influence employees and leaders at all organizational levels.
- Support leader standard work deployment and capability‑building activities.
- Build employee engagement and ownership of continuous improvement initiatives.
- Serve as both a strategic partner to plant leadership and a hands‑on coach on the manufacturing floor.
7. Cost Reduction & Business Performance
- Lead site‑level cost‑out and productivity initiatives.
- Identify opportunities to improve labor efficiency, material utilization, equipment performance, and manufacturing processes.
- Deliver annual savings commitments and support long‑term financial performance.
- Track improvement benefits and validate financial impact.
- Partner with plant leadership and cross‑functional teams to prioritize high‑value initiatives.
- Translate improvement opportunities into measurable business outcomes.
8. Cross‑Functional Collaboration
- Partner with manufacturing, operations, engineering, quality, and supply chain teams.
- Influence stakeholders and communicate improvement priorities effectively.
- Coordinate multiple time‑sensitive improvement initiatives.
- Translate complex operational challenges into clear priorities and actionable plans.
- Maintain momentum across improvement projects and ensure measurable results.
Required Qualifications:
- Bachelor's degree from an accredited institution.
- Minimum of seven (7) years of experience in manufacturing, operations, engineering, quality, supply chain, or another cross‑functional discipline within a - manufacturing environment.
- Minimum of three (3) years of experience in continuous improvement, Lean, Six Sigma, or operational excellence.
- Minimum of three (3) years of experience leading people, projects, and cross‑functional teams.
- Strong understanding of Lean Management Systems and their connection to business strategy, daily operations, and waste elimination.
- Proven analytical, facilitation, and problem‑solving skills.
- Experience applying structured problem‑solving methods, including 8D and statistical analysis.
- Ability to define root causes, validate solutions, and prevent recurrence.
- Demonstrated ability to lead, influence, and develop cross‑functional process improvement teams.
- Ability to prioritize multiple time‑critical tasks and maintain momentum across several improvement initiatives.
- Ability to work as both a strategic partner to leadership and a hands‑on coach on the manufacturing floor.
- Must be able to work in the United States without requiring current or future employment immigration sponsorship.
- Broad knowledge of Lean tools and principles, including: Value Stream Mapping, 5S / Workplace Organization, Continuous Flow Manufacturing, Setup Reduction, Total Productive Maintenance (TPM), Error Proofing, Pull Systems, Standardized Work
Preferred Qualifications:
- Master's degree from an accredited institution.
- Six Sigma Green Belt or Black Belt certification.
- Project management experience or Project Management Professional (PMP) certification.
- Experience or certification in Total Productive Maintenance (TPM).
- Experience in setup reduction and structured problem solving.
- Experience implementing Lean material flow improvement initiatives.
- Experience developing and deploying continuous improvement systems within manufacturing facilities.
- Experience leading Operational Assessments and developing improvement roadmaps.
- Demonstrated success delivering measurable cost savings and productivity improvements.