Manufacturing Manager Fuel Cell Module Assembly

Manufacturing Manager Fuel Cell Module Assembly

Torrington, CT, US, 06790

Summary:

The Manufacturing Manager, Fuel Cell Module Assembly is a critical operational leadership role responsible for module production in a 24/7 manufacturing environment. This individual directly manages all Shift Supervisors across day, evening, and night shifts and is accountable for meeting production targets, controlling production costs, and maintaining rigorous quality standards throughout the final assembly process. The Manufacturing Manager serves as the primary operational bridge between shop floor execution and senior leadership, translating strategic production goals into daily shift-level action.

Essential Functions/Duties and Responsibilities:

Production & Output Management

• Own the daily, weekly, and monthly production output plan for fuel cell module final assembly; ensure shift targets and schedule attainment goals are consistently met or exceeded.

• Monitor and manage throughput across all assembly stages; primarily focusing on module fabrication and stack integration.

• Develop and maintain production capacity models and staffing plans that account for preventative maintenance, shift transitions, and production ramps in a 24/7 operating model.

• Drive continuous improvement initiatives in cycle time, line efficiency, and overall equipment effectiveness (OEE) using structured methodologies (Kaizen, VSM, 5S, PDCA).

• Partner with Planning and Supply Chain to align production schedules with material availability.

Shift Supervision & People Leadership

• Directly manage all Shift Supervisors; provide clear direction, performance expectations, and ongoing coaching to build a high-performing supervisory team.

• Conduct regular one-on-ones and shift overlap meetings to ensure continuity of operations, communication of priorities, and effective shift handoffs with no loss of production time.

• Lead the hiring, onboarding, and development of Shift Supervisors in partnership with HR; establish career development paths and succession planning within the team.

• Foster a culture grounded in accountability, transparency, and respect; maintain a coaching-first leadership approach.

• Administer performance management processes including goal-setting, performance reviews, corrective action, and recognition programs for all direct and indirect reports.

• Manage shift staffing levels, time and attendance, and overtime allocation in compliance with company policy and labor agreements.

Quality Assurance & Compliance

• Serve as owner for all quality metrics within module assembly, including first-pass yield (FPY), defect rates, nonconformance reports (NCRs), and corrective/preventive action (CAPA) closure rates.

• Partner with Quality Engineering to investigate NCRs, lead root cause analysis (RCA) using structured tools (8D, Ishikawa, 5-Why), and implement sustainable corrective actions at the process level.

• Ensure application of standardized work, assembly procedures, and inspection protocols across all shifts; own the review and update cadence for all relevant work instructions.

• Support internal audits, customer source inspections, and third-party quality assessments; drive readiness and follow-up action closure.

• Champion quality culture on the shop floor.

Cost Management & Metric Reporting

• Own and report on the manufacturing cost structure for module assembly operations, including direct labor, consumables, rework costs, scrap costs, and overhead allocation.

• Prepare and present a regular manufacturing performance dashboard to senior leadership covering output rate, cost per unit, quality metrics, and shift efficiency.

• Support the organizations' cost optimization efforts by identifying and executing on cost reduction initiatives through labor efficiency gains, waste elimination, and process optimization.

• Develop and manage the module assembly operating budget; flag variances proactively and provide data-driven recommendations for course correction.

EH&S and Regulatory Compliance

• Ensure all module assembly operations are conducted in full compliance with applicable EH&S regulations, including OSHA standards relevant to high-voltage testing, pressure systems, and chemical handling associated with fuel cell manufacturing.

• Lead incident investigation and near-miss reporting; ensure timely corrective action and communication to the broader team without a culture of blame.

• Enforce and model safe work practices on the floor; integrate EH&S ownership into Shift Supervisor accountabilities and hourly operator training.

Cross-Functional Collaboration

• Work closely with Manufacturing Engineering to introduce new products, process changes, and equipment qualifications into production with minimal disruption to existing output commitments.

• Collaborate with Maintenance to manage planned preventive maintenance (PM) windows and prioritize response to unplanned equipment failures that impact production.

• Interface with Program Management and Customer Service teams to communicate production status, flag risks to committed delivery dates, and provide realistic recovery timelines when needed.

• Support new product introduction (NPI) and the engineering change orders (ECO) in module assembly, ensuring lessons learned are captured and incorporated into standard work.

Key Performance Indicators

• Production Rate; Weekly & monthly run rates

• First-Pass Yield (FPY); Scrap and rework costs

• Non-Conformances: Quantity, cost, and corrective action plan (CAP) closure per schedule

• Cost Per Unit (direct labor + materials) vs. standard

• OEE (Availability x Performance x Quality) for final assembly

• EH&S in Module Assembly; recordables and near-misses

• Headcount vs. plan and overtime percentage of total hours worked

• Training time & records; Staff competencies & onboarding times

Qualifications and Experience:

Required

• Bachelor's degree in Mechanical or Industrial Engineering or a closely related discipline.

• 7+ years of progressive manufacturing operations experience, including at least 3 years in a supervisory or management role.

• Demonstrated experience managing a manufacturing team.

• Proven track record of meeting or exceeding output, cost, and quality targets.

• Fluency with manufacturing quality systems: NCR processes, CAP, RCA methodologies (8D, Ishikawa, 5-Why).

• Experienced creating and maintaining manufacturing cost reporting and KPI dashboards and presenting them to senior leadership.

• Strong working knowledge of production planning tools, ERP/MES systems, and lean manufacturing principles.

• Demonstrated ability to lead through influence, coach supervisory staff, and build a positive, accountable culture.

• Excellent written and verbal communication skills; able to translate operations data into clear, concise messaging.

Preferred

• Experience in fuel cell manufacturing, battery manufacturing, or other electrochemical or power generation systems assembly.

• Familiarity with molten carbonate fuel cells, PEM fuel cells, phosphoric acid fuel cell, or solid oxide fuel cell manufacturing and module assembly processes.

• Six Sigma Green Belt or Black Belt certification; Lean/Kaizen facilitation experience.

• Experience with Monday.com, D365, SAP, Oracle, or comparable MES/ERP platforms for production tracking and reporting.

• Prior experience supporting a manufacturing facility ramp or greenfield production startup.

Work Environment and Physical Requirements

• This role requires regular presence on the manufacturing floor, including periodic off-hours visits to evening and night shifts to maintain management visibility.

• Work environment includes exposure to electromechanical assembly equipment, high-voltage test systems, pressurized gas handling, and industrial cleaning processes; appropriate PPE required per EH&S protocols.

• Ability to stand, walk, and observe assembly operations for extended periods; occasional lifting of components up to 35 lbs.

• Must be available for escalation response during off-hours as needed given the 24/7 operational nature of the role.

All Employees Shall:

• Comply with the EH&S Policy and applicable regulatory and company EH&S rules and requirements.
• Report to supervision conditions or practices that are either unsafe or that may adversely impact the environment, to ensure prompt resolution of potential hazards.
• Attend scheduled EH&S training program.
• Actively support the organization's efforts to meet or exceed EH&S goals and plans.
• Recommend improved EH&S practices.
• Must maintain regular and consistent attendance.

This Job Description is to serve as a guide. It is intended to be flexible and will continue to evolve over time with business needs and demands and may be updated periodically and at the Company's discretion. Nothing in this position description changes or is intended to change the employment at-will relationship with the Company or the terms of any collective bargaining agreement. Employment at-will means that an employee or the Company may terminate the employment relationship at any time, for any reason or no reason at all, with or without notice.

Nearest Major Market: Torrington