Plant Manager

Job Description

Job Description

Description:

 

Plant Manager
Location: United Rolls Inc. In Canton, Ohio
Department: Operations
Reports To: President
FLSA Status: Exempt 

Position Summary  

The Plant Manager is responsible for the overall leadership, performance, safety, quality, and profitability of United Rolls Inc.'s manufacturing operations, including an iron foundry and machine shop specializing in the production of centrifugal spun cast iron rolls for the steel, aluminum, paper, plastics, and other industrial processing industries. This position directs all aspects of production, maintenance, quality assurance, engineering, environmental compliance, and workforce development to ensure on-time delivery of world-class products while maintaining the highest standards of safety, quality, and operational excellence. 

Essential Duties and Responsibilities  

Safety and Environmental Leadership  

• Establish and maintain a strong safety culture throughout the foundry and machine shop operations. 
• Ensure compliance with OSHA, EPA, state environmental regulations, and company safety policies. 
• Lead incident investigations, root cause analysis, and corrective actions. 
• Conduct regular safety audits, risk assessments, and safety training programs. 
• Drive continuous improvement in safety metrics, including reduction of recordable incidents and near misses. 

Operations Management  

• Direct daily operations of the iron foundry, centrifugal casting processes, heat treatment operations, roll finishing, and machine shop activities. 
• Ensure production schedules meet customer delivery requirements while maintaining efficiency and quality standards. 
• Monitor plant productivity, capacity utilization, scrap rates, and operational performance metrics. 
• Coordinate production planning, workflow optimization, and resource allocation. 
• Implement Lean Manufacturing, Six Sigma, and continuous improvement initiatives. 

Foundry Management  

• Oversee all foundry operations including:
• Melting and pouring of iron alloys. 
• Centrifugal casting of rolls. 
• Mold preparation and handling. 
• Heat treatment processes. 
• Metallurgical testing and quality control. 
• Ensure proper process controls are maintained to achieve customer specifications and metallurgical requirements. 
• Drive improvements in yield, casting quality, and process consistency. 

Machine Shop Leadership  

• Manage machining operations involving large CNC and manual equipment used in roll finishing. 
• Optimize machine utilization, tooling performance, setup reduction, and throughput. 
• Ensure proper maintenance and calibration of machine tools and inspection equipment. 
• Support implementation of advanced machining technologies and automation where appropriate. 

Quality Assurance  

• Partner with Quality and Metallurgical teams to ensure product integrity. 
• Lead efforts to reduce defects, rework, customer complaints, and warranty claims. 
• Ensure compliance with ISO and customer quality standards. 
• Review and analyze quality metrics and implement corrective actions. 

Maintenance and Reliability  

• Direct preventive and predictive maintenance programs for foundry and machining equipment. 
• Develop capital improvement and equipment replacement plans. 
• Minimize downtime through effective maintenance planning and reliability strategies. 
• Oversee utilities, plant infrastructure, and critical support systems. 

Financial Management  

• Develop and manage annual operating budgets. 
• Monitor labor, material, energy, maintenance, and overhead costs. 
• Identify and implement cost reduction initiatives. 
• Analyze production and operational data to maximize profitability. 
• Support capital investment planning and ROI analysis. 

Leadership and Workforce Development  

• Lead, coach, and develop supervisors, managers, and hourly employees. 
• Foster employee engagement, accountability, teamwork, and continuous improvement. 
• Support workforce planning, succession planning, and talent development efforts. 
• Collaborate with Human Resources on hiring, performance management, and employee relations. 
• Maintain positive labor-management relationships where applicable. 

Customer and Business Support  

• Support sales and customer service teams by ensuring manufacturing capabilities align with customer requirements. 
• Participate in customer visits, audits, and technical reviews. 
• Work closely with engineering on new product development and process improvements. 
• Maintain strong communication with suppliers and contractors. 

Position Impact  

The Plant Manager plays a critical leadership role in ensuring United Rolls Inc. delivers high-quality spun cast iron rolls safely, efficiently, and profitably while driving continuous improvement and supporting the company's long-term growth objectives. 

Requirements:

 

Qualifications  

Education  

• Bachelor's degree in Engineering, Manufacturing, Metallurgy, Industrial Management, or related field preferred. 
• Equivalent combination of education and industry experience may be considered. 

Experience  

• Minimum 10 years of manufacturing leadership experience. 
• Minimum 5 years in a plant management, operations management, or senior production leadership role. 
• Strong experience in foundry operations, metal casting, steel or iron manufacturing, heavy industrial manufacturing, or related industries. 
• Experience managing machining operations and large CNC equipment preferred. 
• Proven success leading safety, quality, productivity, and continuous improvement initiatives. 

Technical Knowledge  

• Iron metallurgy and centrifugal casting processes. 
• Foundry operations and heat treatment processes. 
• CNC machining and machining best practices. 
• Lean Manufacturing and Six Sigma methodologies. 
• Quality management systems and root cause analysis. 
• Maintenance and reliability management. 
• ERP/MRP manufacturing systems. 
• OSHA and environmental compliance standards. 

Required Competencies  

• Strong leadership and team-building skills. 
• Strategic thinking and business acumen. 
• Excellent problem-solving and decision-making abilities. 
• Strong communication and interpersonal skills. 
• Results-oriented with a continuous improvement mindset. 
• Ability to manage multiple priorities in a fast-paced manufacturing environment. 
• High level of accountability and integrity. 

Key Performance Indicators (KPIs)  

• OSHA Recordable Incident Rate 
• Lost Time Accident Rate 
• On-Time Delivery Performance 
• Production Throughput 
• Scrap and Yield Performance 
• Cost Per Ton Produced 
• Machine Utilization 
• Overall Equipment Effectiveness (OEE) 
• Customer Quality Performance 
• Employee Retention and Engagement 
• Maintenance Downtime 
• EBITDA/Operating Profit Contribution 

Physical and Work Environment Requirements  

• Frequent presence in foundry and machine shop environments. 
• Exposure to heat, noise, dust, moving equipment, and industrial hazards. 
• Ability to walk production areas daily and occasionally climb stairs, ladders, and platforms. 
• Ability to wear required personal protective equipment (PPE).