Plant Manager

Lithotype; Bolingbrook (IL); On-site; USD 120,000 - 180,000; Full time

Job summary

Lithotype in Bolingbrook, IL is seeking a Plant Manager to direct all production departments and ensure on-schedule, high-quality output while controlling costs. You will lead rewind, press, lamination and shipping and receiving, drive safety, quality and lean improvements, and coordinate with senior leadership on budgets and strategic plans.

The ideal candidate has 5+ years of manufacturing leadership in flexible packaging, deep knowledge of wide-web flexography, lamination, and ERP systems,

Qualifications

• Must have minimum 5 years of manufacturing experience in flexible packaging.
• Minimum 5 years of plant management or senior operations leadership.
• Experience with wide-web flexographic printing and solventless lamination.
• Familiarity with BRCGS, GMP, and safety requirements.
• Strong Lean manufacturing, 5S, DMAIC, and TPM experience.

Responsibilities

• Direct and manage all manufacturing activities across rewind, press, lamination, shipping/receiving.
• Develop manufacturing plans and policies to meet quality and cost targets.
• Collaborate with senior staff on budgeting and long-term plans.
• Drive continuous improvement, safety, and compliance with BRC/GMP.

Skills

Lean Six Sigma

Operations leadership

Plant management

Production scheduling

Quality assurance

Education

Bachelor's degree in Engineering

Tools

ERP systems

CAPEX planning

Budgeting

Job description

The Plant Manager directs, manages and coordinates activities of all production departments to ensure that approved company products are manufactured on-schedule and within quality standards and cost objectives. Manages and implements manufacturing strategies and objectives concerned with production of company products to ensure the achievement of company goals.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

1. Direct and manage all manufacturing activities of the following departments - rewind, press, lamination and shipping/receiving. Ensure the production of high-quality products to meet customer print quality requirements, while achieving them in a highly efficient and cost-effective manner. Follow company directive and never compromise safety and/or quality for productivity.

• Make self available to assist pressmen in troubleshooting press problems and attaining a level of quality that meets or exceeds customer expectations and waste/productivity targets, either through press-side assistance or direction.

2. Develop the manufacturing plan and establish and implement policies and procedures for maintaining high standards of manufacturing operations to ensure that products conform to established customer and company quality standards.

• Achieve optimum employee levels with least amount of overhead and raw material costs to meet annual budgetary plan.
• Formulate and recommend manufacturing policies and programs that guide the organization in maintaining and improving its competitive position and the profitability of the operation.
• Direct and monitor department supervisors to accomplish goals of the manufacturing plan, including waste reduction and efficiency improvements, consistent with established manufacturing and safety procedures. Act as liaison between department supervision/subordinate levels, as well as executive/department manager levels and the sales team to inform personnel of communications, decisions, policies and all matters that affect their performance, attitudes and results.
• Identify, recommend and implement changes to improve productivity and reduce cost and scrap, monitor scrap and rework data. Direct the establishment, implementation and maintenance of production standards.
• Initiate and coordinate major project needs (e.g., plant layout changes, installation of capital equipment, major repairs, etc.). Continuously searches for equipment investment opportunities that will further improve safety, efficiency, capacity, as well as ensure we meet organizational goals. Participates in the selection of printing and rewind equipment and consumable vendors.
• Foster a culture of teamwork, collaboration, operations excellence and continuous improvement through listening to employees, acting on ideas, and following through. Work effectively and relate well with others. Exhibit a professional manner in dealing with others, working to maintain constructive working relationships.
• Direct and oversee the job engineering process.
• Utilize all company tools in achieving corporate performance metrics, including layout of equipment, workflow, assembly methods, and work force utilization.
• Develop and implement a maintenance program for all equipment to assure minimal down time.
• Plan and direct production activities and establish production priorities for products in keeping with effective operations and cost factors.
• Consult with engineering personnel related to modification of machines and equipment in order to improve production and quality of products.
• Direct continuous improvement and process improvement efforts and activities on the plant floor. Implement processes and procedures consistent and in alignment with BRC, AIB and G.M.P guidelines for food packaging products.
• Review and analyze production, quality control, maintenance, and operational reports to determine causes of nonconformity with product specifications and operating or production problems.
• In partnership with Quality Control, assuring products are of the highest quality prior to being sent to customers.
• Oversee and manage the company’s safety program in Bolingbrook to provide an adequate and safe working environment. Assure compliance with all safety policies and regulations.

3. Collaborate with company officers and senior staff members in the development and formulation of long and short-range planning, policies, programs, objectives and annual budgets.

• Hire, train, develop and evaluate staff in collaboration with Human Resources to ensure strong team dynamics and excellent employee relations.
• Work closely with Human Resources to ensure careful and proper handling of all employee issues, including corrective action as necessary on a timely basis and in accordance with company policy.
• Ensure compliance with current federal, state, local and contract regulations.
• Keep current on information and technology affecting functional areas to increase innovation and ensure compliance.
• Perform miscellaneous duties and projects as assigned and required.

Strong preference for Lean Six Sigma Green Belt or Black Belt certification, supported by demonstrated project results.

The candidate should have successfully implemented:

• Lean Manufacturing principles and 5S programs.
• Six Sigma DMAIC methodology.
• Overall Equipment Effectiveness (OEE) measurement and improvement.
• Root Cause Analysis (RCA) and corrective action programs.
• Standardized work instructions and operating procedures.
• SMED (Single-Minute Exchange of Die) or comparable setup reduction techniques.
• Kaizen events and structured continuous improvement projects.
• Statistical Process Control (SPC).
• Preventive maintenance and Total Productive Maintenance (TPM).

Experience Required:

• Must have a minimum 5 years of manufacturing experience, in flexible packaging.
• Minimum 5 years of plant management or senior operations leadership experience.
• Extensive knowledge of wide-web flexographic printing, including press setup, registration, color management, ink systems, and troubleshooting.
• Experience with solventless lamination, slitting, rewinding, and converting operations.
• Understanding of flexible packaging substrates, films, adhesives, inks, and material specifications.
• Experience managing multiple production lines and shifts.
• Working knowledge of production scheduling, estimating, inventory management, and ERP systems.
• Familiarity with BRCGS Packaging Materials certification, GMP, and manufacturing safety requirements.
• Experience with offset packaging printing is a plus.