Operations Manager

Operations Manager

The Operations Manager is responsible for directing and coordinating all daily activities within the blown film, extrusion, and converting plant. This role ensures that production targets are met safely, efficiently, and to the highest quality standards. The Operations Manager oversees production schedule attainment, quality control and product trials while driving continuous improvement initiatives to optimize resin usage, minimize downtime and scrap rates, while achieving the plant's operational targets.

A reasonable estimate of the current range is $125,000 to $170,000 + performance based bonus + benefits. The range displayed on each job posting reflects the minimum and maximum target salaries for the position across all US locations. Within the range, individual pay is determined by job-related skills, experience, and relevant education or training. At Novolex, it is not typical for an individual to be hired at the top of the range for their role and compensation decisions are dependent on the facts and circumstances of each case.

The benefits for this role include 401(k) plan with company match, comprehensive medical, dental, and vision insurance, flexible spending and health savings accounts, paid vacation, and sick days, free onsite clinic, paid parental leave, paid holidays and wellness program.

Essential functions and key responsibilities include:

Safety & Compliance

• Champion a zero-incident safety culture, ensuring strict compliance with OSHA regulations and company Environmental, Health, and Safety (EHS) policies.

• Conduct regular safety audits, lead incident investigations, and implement corrective actions.

• Maintain high standards of 5S and housekeeping across the production floor, resin storage, and warehouse areas.

Production & Operations Management

• Oversee the daily operation of blown film extrusion and converting lines, ensuring optimal throughput and Overall Equipment Effectiveness (OEE).

• Collaborate with scheduling and supply chain teams to optimize production runs, minimize changeover times, and manage resin inventory/variances.

• Monitor daily production reports to track yield, scrap rates, and machine uptime, taking immediate action to address variances.

• Co-Manage plant maintenance programs, balancing preventative maintenance schedules with production demands to ensure equipment reliability.

• Be the primary conduit for all CSR, Sales and Direct customer updates/communications for all plant activities.

Quality Assurance

• Partner with the Quality team to ensure all Flexible films, Roll Stock and Bags meet customer specifications for internal and customer specific properties.

• Identify root causes of quality defects and implement permanent corrective actions using a robust RCCA process such as Novolex A3.

• Ensure adherence to ISO standards and SQF food-safe packaging certifications.

• Review Document specifications to ensure that equipment/processes meet the required standards with an escape rate of less than 1%.

Leadership & Team Development

• Lead, mentor, and develop a team of Departmental managers, shift supervisors, lead operators, and technicians.

• Establish clear performance metrics and KPIs for the production team.

• Identify skills gaps and oversee technical training programs for operators on blown film processes, resin blending, Flexo printing, Bag making and rewind operations.

• Foster a collaborative environment that encourages employee engagement and problem-solving at the floor level.

Continuous Improvement & Financial Management

• Drive Lean Manufacturing, Six Sigma and TOC initiatives to reduce waste, lower conversion costs, and improve process flow.

• Manage the operational budget, keeping tight control over labor costs, overtime, and operational expenditures.

• Assist in evaluating, specifying, and installing new capital equipment

Qualifications and requirements include:

Education & Experience

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Operations Management, or Business Administration preferred

• 7–10 years of progressive manufacturing leadership experience

• Proven track record in a plant leadership or senior management capacity.

Technical Skills

• Knowledge of polymer science as it relates to blown film is preferred.

• Knowledge of Flexo printing and Bag making on various Flexible films for Food and Industrial applications is preferred.

• Strong financial acumen with experience managing operational budgets and understanding manufacturing P&L.

• Proficiency with ERP systems and production monitoring software (preferably SAP)

• Experience with corporate Operational excellence initiatives, such as Novolex OPX360, and working in an environment of accountability through RCCA/KPI and weekly reporting on operational activities.

Key Competencies

• Strong analytical and problem-solving skills with a data-driven approach.

• Excellent communication skills, capable of bridging the gap between shop-floor operators and executive leadership.

• Ability to thrive in a fast-paced, 24/7 manufacturing environment.