Director of Operations

Description

Reports To

Chief Operating Officer

FLSA Status

Salary Exempt

Summary

Responsible for all aspects of the daily operation of the converting facility, including safety, quality, production, maintenance, and delivery performance for our contract manufacturing facility. Provides oversight of machinery, plant, and equipment engineering, maintenance strategy, and capital projects. Assures that company philosophy, goals, and vision are understood and fulfilled. Serves on the leadership team and acts as the intermediary with middle and upper management. Builds and develops a high-performing workforce and creates and maintains an atmosphere that values input from all employees.

Scope

Leads approximately 7 direct and 100 indirect reports across 3 shifts; manages an annual operating budget of approximately $85M.

Essential Functions and Responsibilities

• Creates and promotes a safe and efficient working environment; leads the site safety program and ensures compliance with OSHA and other applicable regulations.
• Works with quality assurance on quality improvements and facilitates root cause problem-solving; supports maintenance of the ISO 9001 quality management system and BRCGS food safety certification, including audits and corrective actions.
• Champions continuous improvement using Lean and other structured problem-solving methods to improve OEE, reduce waste and changeover time, and lower conversion costs.
• Responsible for all daily issues with safety, quality, manufacturing, customer satisfaction, delivery, and maintenance and resolves them in a timely and professional manner.
• Develops, implements, and monitors day-to-day operational systems and processes that provide visibility into goals, progress, and obstacles for our key initiatives.
• Leverages ERP, MES, and production data to drive decisions; supports automation and digital initiatives that improve throughput, quality, and real-time visibility.
• Oversees activities of the managers responsible for the daily manufacturing operation.
• Evaluates performance of direct reports as well as hires and terminates managerial production staff.
• Leads workforce planning, including recruiting, onboarding, cross-training, and skills development programs for production and maintenance personnel.
• Develops succession plans for key roles and implements engagement and retention initiatives.
• Works with supervisors and Human Resources on disciplinary concerns and employee relations matters.
• Keeps current with manufacturing technology, including equipment, building and grounds, environmental, and safety.
• Coordinates with maintenance, engineering, and production on upgrades to existing equipment and installing new equipment.
• Provides technical support and resources to maintenance and engineering.
• Develops and manages the operating budget and is responsible for addressing variances.
• Leads the annual capital plan, including project justification (ROI), equipment selection, installation, and commissioning, delivering projects on time and within budget.
• Oversees production planning and scheduling to meet customer commitments; participates in sales and operations planning (S&OP) and manages capacity, labor, and inventory to support contract manufacturing customers.
• Serves on the company leadership team and participates in strategic planning.
• Works with customer service, sales, suppliers, and other outside organizations as required to solve problems or answer concerns.
• Performs other duties as assigned by the Chief Operating Officer.

Preferred Aptitudes/Eligibility Considerations

• Bachelor’s degree in Management or Engineering (MBA preferred) or equivalent progressive work history.
• Minimum of ten years of manufacturing experience, including at least five years in a leadership role managing managers. Experience in converting, packaging, or contract manufacturing is a plus.
• Ability to work constructively with people inside and outside the organization effectively and respectfully.
• Strong analytical ability for problem-solving and exceptional communication skills.
• Excellent planning and organizational skills.
• Prior experience in Lean Manufacturing (certifications preferred).
• Working knowledge of ISO 9001 quality systems and GFSI food safety standards (BRCGS preferred).
• Demonstrated experience leading capital projects and maintenance/reliability programs.
• Proficiency with ERP/MES systems, Microsoft Office, and data analysis tools.
• Ability to effectively build and lead a high-performing and engaged team in a collaborative environment.
• Possess an excellent working knowledge of business operations and manufacturing.

Physical Considerations

• Exposure to frequent movement of motorized equipment throughout production, including forklifts, trollies, and others.
• Must use hands to touch, feel, type, and manipulate equipment.
• Lift items infrequently up to 50 pounds.
• Must wear required personal protective equipment (PPE) and follow Good Manufacturing Practices (GMP) and food safety requirements in production areas.
• Ability to sit, bend, stoop, climb and stand for long periods of time in one place for most of an 8-hour shift

Performance Criteria

• Safety performance (recordable incident rate, near-miss reporting, safety audit results)
• Overall Equipment Effectiveness (OEE) versus target
• Quality performance (customer complaints, ISO 9001 and BRCGS audit results)
• Employee engagement, retention, and development of successors
• Capital project execution on time and within budget
• Customer satisfaction and on-time, in-full (OTIF) delivery
• Plant financial performance (budget variance, cost reduction, and contribution to profitability)

Work Environment

• 40-45 hours/week rotating between the production floor and an office environment.
• Occasional travel (less than 10%) for customer, supplier visits.
• Extra hours, including off-shift, weekend, and on-call availability, as needed to support production, planned shutdowns, and emergencies.

Compensation

• Salary range: commensurate with experience, plus bonus, and a comprehensive benefits package.

Equal Employment Opportunity

FCI is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, veteran status, or any other characteristic protected by law.

Disclaimer

This job description is not intended to be all-inclusive and may be modified at any time at the discretion of the Company. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this position. This description does not constitute an employment contract; employment is at-will.