Plant General Manager

RON SUNSHINE ASSOCIATES LLC; Lexington (KY); On-site; USD 180,000 - 250,000; Full time

Job summary

Ron Sunshine Associates LLC in Lexington, KY seeks a Plant General Manager to lead a complex automotive manufacturing operation. You will oversee production, quality, safety, and continuous improvement to meet customer expectations and drive profitability.

The ideal candidate has hands-on leadership, proven plant P&L ownership, and deep experience with Lean manufacturing, APQP/PPAP, and cross-functional program launches in automotive settings.

Qualifications

• Bachelor's degree required.
• Proven experience leading a complex manufacturing plant or major operation.
• Track record of improvements in quality, cost, delivery, safety, productivity, profitability.
• Knowledge of automotive quality and launch methodologies: APQP, PPAP, FMEA, Control Plans, problem-solving.
• Lean manufacturing and continuous improvement expertise.
• Experience with new product launches in automotive.
• Strong plant-level financial management, budgeting, forecasting, cost control, and P&L responsibility.
• Ability to lead and retain high-performing teams.
• Analytical, problem-solving, and decision-making skills.
• Excellent interpersonal, communication, leadership, organizational skills.
• Ability to delegate while maintaining accountability.
• High professionalism and integrity.
• Ability to operate in fast-paced automotive environment.
• Understanding of manufacturing quality, safety, delivery, productivity, cost systems.

Responsibilities

• Provide leadership for plant operations including production, quality, engineering, maintenance, materials, safety, delivery, and cost performance.
• Develop and execute operational strategies that support objectives, customer requirements, and long-term growth.
• Ensure the plant meets quality, delivery, productivity, cost, and customer satisfaction objectives.
• Maintain ISO compliance and customer-specific quality systems.
• Drive a culture of quality, customer focus, accountability, and continuous improvement.
• Lead Lean, Six Sigma, standard work, waste reduction and operational excellence initiatives.
• Analyze processes and metrics to improve efficiency, productivity, quality, throughput, cost, and profitability.
• Establish KPIs and management systems to monitor performance.
• Develop and manage annual operating plan, budget, forecasts, and financial performance.
• Maintain accountability for plant P&L, cost control, labor efficiency, scrap, overtime, inventory.
• Ensure response to customer quality issues, warranty concerns, delivery issues, escalations.
• Provide leadership for new product and new program launches from launch to production.
• Ensure execution of automotive launch and quality processes (APQP, PPAP, FMEA, control plans).
• Collaborate with engineering, quality, sales, materials, and operations for launches and support.
• Maintain safe work environment and compliance with safety policies/regulations.
• Prepare for emergencies, supply disruptions, production interruptions.
• Lead, develop, retain employees; foster trust, accountability.
• Set performance expectations and hold leadership teams accountable.
• Conduct performance evaluations and provide coaching.
• Communicate effectively across all levels; foster open communication.
• Proactively identify and resolve operational, quality, customer, employee issues.
• Develop relationships with customers and suppliers.
• Promote a positive, performance-driven culture.

Skills

Lean Manufacturing

Six Sigma

Problem-solving

Team leadership

P&L management

Quality systems

Financial management

Continuous improvement

Operational excellence

Education

Bachelor's degree

Job description

Plant General Manager

Candidates MUST have proven experience and a demonstrated track record of success leading complex manufacturing operations.

Position Summary

The Plant General Manager is responsible for the overall leadership, operational performance, and financial results of the manufacturing facility. This role provides leadership across production, quality, safety, delivery, cost, engineering, and continuous improvement, ensuring the plant consistently meets or exceeds customer and company expectations.

The ideal candidate is a hands‑on, results‑oriented manufacturing leader with demonstrated success leading a complex automotive manufacturing operation. The successful candidate will have a strong understanding of customer requirements, quality systems, Lean Manufacturing, continuous improvement, financial management, and the demands associated with supporting major automotive customers.

This individual must be capable of building high‑performing teams, driving accountability, solving complex operational problems, and delivering sustainable improvements in quality, cost, delivery, productivity, safety, and profitability.

Key Responsibilities

• Provide overall leadership and direction for plant operations, including production, quality, engineering, maintenance, materials, safety, delivery, and cost performance.
• Develop and execute operational strategies that support company objectives, customer requirements, and long‑term business growth.
• Ensure the plant consistently meets or exceeds quality, delivery, productivity, cost, and customer satisfaction objectives.
• Maintain overall accountability for compliance with ISO standards, customer‑specific requirements, and applicable quality systems.
• Drive a culture of quality, customer focus, accountability, and continuous improvement throughout the organization.
• Lead and implement continuous improvement initiatives utilizing Lean Manufacturing, Six Sigma, problem‑solving, standard work, waste reduction, and other operational excellence methodologies.
• Analyze manufacturing processes and plant performance metrics to identify opportunities to improve efficiency, productivity, quality, throughput, cost, and profitability.
• Establish and maintain appropriate KPIs and management systems to monitor plant performance and drive accountability.
• Develop, monitor, and manage the plant's annual operating plan, budget, forecasts, and financial performance.
• Maintain accountability for monthly and annual plant P&L results, including cost control, labor efficiency, scrap, overtime, inventory, and productivity.
• Ensure effective response to customer quality issues, warranty concerns, delivery issues, and other customer escalations.
• Provide leadership and oversight for new product and new program launches, ensuring successful execution from launch through production.
• Ensure effective execution of applicable automotive launch and quality processes, including APQP, PPAP, FMEA, control plans, and related customer requirements.
• Work closely with corporate and plant‑level engineering, quality, sales, materials, and operations teams to ensure successful program launches and ongoing customer support.
• Establish and maintain a safe work environment while ensuring compliance with company safety policies, procedures, and applicable regulatory requirements.
• Ensure the organization is prepared to effectively respond to plant emergencies, supply disruptions, production interruptions, and other operational challenges.
• Lead, develop, and retain employees while fostering a culture of trust, accountability, teamwork, ownership, and continuous improvement.
• Establish clear performance expectations and hold leadership teams accountable for achieving plant objectives.
• Conduct performance evaluations and provide coaching, development, and corrective direction when necessary.
• Communicate effectively with employees at all levels of the organization and create an environment of open communication and accountability.
• Proactively identify and resolve operational, quality, customer, employee, and performance issues.
• Develop and maintain strong working relationships across all functional areas of the organization and with key customers and suppliers.
• Promote a positive, professional, and performance‑driven culture throughout the facility.

Education & Qualifications

• Bachelor's degree required.
• Proven experience successfully leading a complex manufacturing plant or major manufacturing operation.
• Demonstrated track record of delivering measurable improvements in quality, cost, delivery, safety, productivity, and profitability.
• Working knowledge of automotive quality and launch methodologies, including APQP, PPAP, FMEA, Control Plans, and structured problem‑solving.
• Strong background and working knowledge of Lean Manufacturing, continuous improvement, and operational excellence methodologies.
• Proven experience leading new product and new program launches within an automotive manufacturing environment.
• Strong understanding of plant‑level financial management, budgeting, forecasting, cost control, and P&L responsibility.
• Demonstrated ability to lead, develop, motivate, and retain high‑performing teams.
• Strong analytical, problem‑solving, and decision‑making skills.
• Excellent interpersonal, communication, leadership, and organizational skills.
• Ability to effectively delegate responsibility while maintaining accountability for results.
• High degree of professionalism, integrity, tact, and diplomacy.
• Ability to operate effectively in a fast‑paced, high‑accountability automotive manufacturing environment.
• Strong understanding of manufacturing quality, safety, delivery, productivity, and cost systems.

The ideal candidate will demonstrate:

• Strong automotive supplier experience
• Proven plant leadership and P&L ownership
• A track record of operational improvement and turnaround
• Strong Lean/continuous improvement expertise
• Experience with automotive launches and customer requirements
• Exceptional people leadership and team development
• A strong sense of urgency, accountability, and ownership
• The strongest candidates will have a history of taking full ownership of complex automotive manufacturing operations and consistently delivering sustainable improvements in plant performance, customer satisfaction, and profitability.