Director of Forge Manufacturing Operations

Job Description

Job Description

Director of Forge OperationsPosition Summary

The Director of Forge Operations is responsible for leading, strategizing, and overseeing all day-to-day and long-term manufacturing operations within the forge facility to ensure safe, efficient, and cost-effective production of high-quality products. This executive role provides leadership and strategic direction across multiple manufacturing departments, including steel forging, precision machining, heat treatment, and primary support functions. The Director of Forge Operations drives operational excellence through continuous improvement, talent development, strategic production planning, quality assurance, and strict adherence to safety and regulatory standards.

The ideal candidate is an executive leader with extensive operational experience in heavy manufacturing environments and a deep background in forging, machining, and heat treatment operations.

Essential Duties and ResponsibilitiesOperational Leadership

• Direct and coordinate plant-wide manufacturing activities across all forge operations to meet production schedules, quality standards, and customer requirements.

• Oversee multi-departmental operations, including:

  • Closed-die forging press lines

  • Mechanical and hydraulic press operations

  • Machining and finishing departments

  • Heat treatment furnaces and operations

  • Material handling and workflow orchestration

  • Secondary processing and finishing

• Monitor production metrics and implement strategic corrective actions to improve plant efficiency, throughput, and equipment utilization.

• Ensure effective cross-departmental alignment and communication to maximize productivity and eliminate operational bottlenecks.

• Establish facility goals and Key Performance Indicators (KPIs) related to safety, quality, productivity, delivery, and operational cost.

Safety and Environmental Compliance

• Champion an uncompromising culture of safety and environmental stewardship throughout the facility.

• Ensure full compliance with OSHA regulations, local environmental standards, and internal safety policies.

• Oversee routine safety audits, risk assessments, and incident investigations.

• Lead root-cause analysis and preventive action programs (CAPA) to eliminate workplace hazards and minimize risk.

• Ensure comprehensive safety training and certification programs are maintained across all operational levels.

Quality Management

• Partner with Quality Leadership to ensure all products meet or exceed customer specifications and industry quality standards.

• Investigate non-conformances and implement permanent corrective actions to prevent recurrence.

• Drive root-cause analysis and continuous improvement initiatives targeting scrap and rework reduction.

• Ensure strict process controls, testing protocols, and inspection procedures are maintained across all shifts.

Employee Leadership and Development

• Lead, coach, mentor, and build high-performing teams, including department managers, supervisors, engineers, and hourly personnel.

• Foster a culture of accountability, engagement, team cohesion, and continuous professional development.

• Optimize workforce strategy and headcount planning to align with production demand.

• Lead talent acquisition, performance evaluations, succession planning, and disciplinary processes.

• Support labor relations strategies and administer operational policies consistent with collective bargaining agreements where applicable.

Continuous Improvement & Operational Excellence

• Champion Lean Manufacturing, Six Sigma, and continuous improvement methodologies across all plant operations.

• Identify structural inefficiencies, eliminate waste, optimize labor utilization, and execute cost-reduction initiatives.

• Sponsor Kaizen events and major process-improvement projects.

• Utilize operational data and advanced reporting to drive strategic decision-making and continuous improvement.

Maintenance and Equipment Reliability

• Partner with Plant Maintenance leadership to drive Total Productive Maintenance (TPM) and minimize unplanned downtime.

• Guide preventive and predictive maintenance strategies for heavy press machinery, furnaces, and auxiliary equipment.

• Oversee capital improvement projects (CapEx), equipment installations, and major facility upgrades.

• Evaluate machinery performance, technology needs, and ROI to recommend strategic capital investments.

Planning, Financial Management & Cost Control

• Collaborate with Production Planning, Procurement, and Supply Chain teams to ensure seamless material flow and on-time order fulfillment.

• Manage operational budgets, labor allocation, scrap costs, and overtime expenses to achieve financial targets.

• Develop and execute strategic plans to drive profitability and control unit manufacturing costs.

• Prepare operational reporting and communicate plant performance metrics directly to executive leadership.

QualificationsEducation

• Bachelor's degree in Engineering (Mechanical, Industrial, or Metallurgical), Manufacturing Technology, Operations Management, or a related field required.

• Master's degree or MBA preferred.

• An equivalent combination of formal technical education and extensive senior manufacturing leadership experience will be considered.

Experience

• Minimum of 8–10+ years of operational leadership experience within a forging, metal forming, heavy machining, or heavy industrial manufacturing environment.

• Minimum of 5 years of senior management experience directing multi-departmental operations and large operational teams.

• Demonstrated hands-on experience overseeing:

  • Open/closed-die forging operations

  • CNC/Precision machining processes

  • Metallurgical heat treatment operations

  • Master scheduling and workflow optimization

• Experience leading within a unionized manufacturing environment preferred.

Knowledge, Skills, and Abilities

• Deep technical understanding of metal forging, metallurgy, machining, and heat-treating operations.

• In-depth knowledge of OSHA regulations, environmental guidelines, and industrial safety management.

• Proven track record of strategic leadership, organizational development, and team building.

• Strong analytical, root-cause problem-solving, and executive decision-making capabilities.

• Solid financial acumen with experience managing departmental P&Ls, operational budgets, and CapEx projects.

• Proficiency with Enterprise Resource Planning (ERP/MRP) systems, CMMS, and Microsoft Office Suite.

• Certified expertise or practical application in Lean Manufacturing, 5S, Value Stream Mapping, and Six Sigma techniques.

Work Environment

This position operates primarily within a heavy industrial forge facility. The Director of Forge Operations maintains an active floor presence around forging presses, heavy machinery, heat treatment furnaces, and material handling zones to support team members, resolve active operational challenges, and lead plant-floor improvements.

Key Performance Indicators (KPIs)

• Total Recordable Incident Rate (TRIR) and plant safety compliance

• Schedule attainment and throughput volume

• Overall Equipment Effectiveness (OEE)

• Scrap, rework, and material yield rates

• Labor efficiency, overtime management, and operational budget variance

• On-Time In-Full (OTIF) delivery metrics

• Workforce retention, engagement, and leadership succession

• Lean implementation savings and CapEx project execution success