Plant Director - Elgin - Coregistics

Description

Position Title: Plant Director Location: Elgin, IL Internal/External Posting: External AI Applicant Selection Used: No Salary Range: $120,000 - $150,000
POSITION SCOPE :
Plant Director is responsible for directing, managing, and optimizing the overall operations of one or more plants or other production facilities. Drives organizational policies and makes decisions guiding productivity, quality, and cost efficiency of plant operations. Establishes systems to collect metrics, analyze productivity and set performance targets that will meet revenue and cost goals. Leads the development and deployment of organization's practices focused on quality and continuous improvement. Ensures robust plant safety and security procedures and training are in place and that operations are in compliance with all required regulations. Leads any labor relations activities involving the plant. Directs plant level support functions including finance, engineering, materials, quality assurance, and human resources to ensure alignment with overall plant operations.
Manages a departmental sub-function within a broader departmental function. Creates functional strategies and specific objectives for the sub-function and develops budgets/policies/procedures to support the functional infrastructure. Deep knowledge of the managed sub-function and solid knowledge of the overall departmental functions. Directing all aspects of Operational Excellence throughout the facility. He/She ensures that the facility's initiatives are being developed, continuously improved and implemented consistently across all sites, with the needs of the production facilities for continually improving key performance indicators and ensuring that new process/project introductions are introduced into production in a more timely and efficient manner, along with improving quality, remove waste and reduce cost.
REPORTS TO :
Chief Operating Officer
Requirements
Essential accountabilities:

• Operational Results. Understanding, tracking, and improving KPIs is vital to the Plant Director's success and the success of his organization. KPIs include operating efficiencies, financial performance, safety, labor utilization, inventory accuracy, product quality, and adherence to operating procedures.
o Required expectations/metrics:
i. Production Requirements:
1. Uptime is 100%
a. Production lines start on time, breaks start/end on time, lines run until shift ends) and with minimal downtime
b. Downtime must be measured on all lines every day to establish measurement markers based on nature of work, etc.
c. (systemic capture of pallets per man hour put-away, etc)
2. Standing Planning Meeting/Reporting:
a. Detailed focused effort on planning regarding contingencies when insufficient labor or unavailable WIP and customer product occurs
ii. Line Lead meetings
1. Daily - Attend and ensure meetings are occurring and discussing previous day performance, along with outlining expectations are for today (drives education and skill of Line Leads)
2. Weekly - Host, hour long Line Lead meeting off of the production floor, focused on line lead development
3. Implement Line Lead Scorecard: to capture all data and show trends, which helps communicate expectations along with detailed needed to communicate required changes when necessary
iii. Department stand-Up Meetings: Attend a different start up meeting every day
Gemba Walks: daily, provide findings and report updates
1. **If these are complete, improvement in core objectives 1& 2 should be improved.
iv. Operating Efficiencies:
1. Minimum 100% target Operating Efficiencies (OE) at all times, within first 30 mins of production startup, 100% required
v. Safety:
1. OIR
vi. Inventory Requirements:
1. Reconciliation of all transactional bins in WMS Daily
2. Daily Cycle Count and reconciliation, completed before leaving each night
3. Root cause of inventory discrepancies identified and communicated, completed prior to leaving each night
4. Production Returns completed daily, if applicable
5. Implement Project Plan for wall-to-wall (PI), in conjunction with finance department and manage process efficiently and effectively as needed- 99.9% accuracy required
vii. Warehouse/Shipping/Receiving:
1. Analysis and near-term options developed for dock housekeeping
2. Dock is clear physically & systematically by end of shift every night
3. Inventory accuracy
a. All shipping & receiving discrepancies are resolved by EOD
4. Maintain warehouse safety (leaning pallets, speed of forklifts, degrading pallets)
5. Visual Factory (5S)
6. Develop basic metrics
a. Establish and monitor receiving rates
b. Metrics to be communicated to planning
viii. Account Management
1. Operational Silence: Identify and eliminate any potential customer noise
2. Be the Customer:
a. Ensure customer reporting is completed, accurate and timely.
b. Respond to all customer requests and inquiries, same day, with informative and appropriate responses.
c. Hero Cards - reported daily
3. Reporting:
a. Production matrix,
b. Daily Activity Report
c. Shipping reports, etc.
4. Cost Recovery: Ensure all cost recovery opportunities are captured, approved and documented.
a. 8% monthly minimum invoiced
5. Invoicing: Ensure all invoicing is completed, accurate and timely, must be completed daily.
6. Attend all customer meetings, conference calls, and requested events.
7. Ensure requirements (i.e. conference numbers, GoTo meetings links, reports, presentations, food requirements, agenda, attendees overviews, etc....) are staged and ready for meeting start accordingly.
8. Direct, develop, manage and maintain reporting requirements for all customer information (dashboard formats, or proper reporting structure) and accessible to corporate and appropriate audience when necessary.
9. Cross-check all billing activities to ensure accuracy and inclusion and submit daily
10. Email all customer feedback (positive & negative) to corporate
11. Up to date dashboard reports for internal and customer reporting requirements

• Cost Control. With full P&L responsibility, the Plant Director must constantly manage all facility costs. Controllable costs include, but aren't limited to, staff, labor, supplies, maintenance, materials, contracted support, utilities, etc..

• Requirements:
o Manage, maintain and approve all purchase orders, receiving and invoicing documents to efficiently process costs from beginning to end.
o Manage all vendor activity within the facility, ensuring accurate time management and records are maintained and audited for invoice processing and reporting requirements.
o Maintain and management monthly expense reports, along with associated receipts to report accurate financial information
o Manage, maintain and audit staffing and FTE hours to control costs and efficiently manage responsibilities
o Labor reconciliated daily and reports provided to agencies weekly for invoice

• Quality Assurance. It is our position that the products we deliver and the data we provide can be perfect in our customer's eyes. With the help of his quality department, the Plant Director ensures all products meet or exceed customer requirements and that all data is accurate and timely.

• Facility Management. The Plant Director has responsibility to maintain his building and equipment in top, "tour ready" shape and that the facility complies with all internal, customer, and 3rd party standards. This includes, but is not limited to pest control, cGMPs, security, and safety.
o Requirements:
§ Security Management Responsibilities

• Perimeter security walks (ensure all entry points are secured or monitored)

• Management Coverage: control schedules to ensure management is onsite during operating hours
§ Alarm Management:

• Ensure only appropriate FTE managers have access to alarm codes - enabling/disabling alarm system (part-time and labor associates are NOT allowed access to alarm system)

• Ensure alarm company has appropriate managers listed to contact (GM, Operations Manager, VP Operations, CEO) in case of emergency/necessity

• Develop, manage and monitor successful security procedures, ensuring that they are followed by all employees and staffing associates and that the safety and security of the building and its contents, including labor are always protected.
§ Building costs: repairs and maintenance
§ Equipment costs and maintenance requirements

• PM Management of all equipment

• Audit Success. Our facilities are frequently audited by both customers and 3rd Party agencies. It is the General Manager's responsibility to ensure we exceed standards on all audits.

• New Business Solutions. New business opportunities, with both existing and new customers will be presented to the Plant Director frequently. The Plant Director must be able to quickly design a solution, build the operating model, determine costing, and communicate with the sales organization or directly with the potential customer, as well as successfully executing the plans.

• Human Resources. Our business model requires an extremely flexible and agile workforce that delivers perfect service at the lowest possible cost. This workforce will consist of permanent employees, part-time employees, seasonal employees, contractors, and temporary employees of varying degrees of skill and education. It is the responsibility of the Plant Director to recruit, train, and manage this diverse, flexible workforce.
o Requirements:
1. Manage and maintain personnel requirements and reporting structure to ensure a successful, efficient and cost effective production facility.
2. Manage recruiting, hiring, and onboarding process for all NJ new personnel and follow up with 90 day and yearly performance reviews to further develop, train and provide feedback to all appropriate personnel.
3. Develop, manage and maintain cross function bench strength for all personnel to efficiently manage all requirements necessary, not only for New Jersey facilities but also assist national facilities when necessary.
4. Drive corporate culture through leadership, fellowship and management activities.
5. Final approval of all direct report's timecards in payroll processing system.

• Customer Relationship Management. The Plant Director is ultimately responsible for the relationship with the customer from both an operations and sales perspective. Additionally, the GM will often interface with potential new customers at industry functions, during tours, and during presentations.
DISCLAIMER: This is not necessarily an exhaustive list of all responsibilities, duties, skills, efforts, requirements or working conditions associated with the job. While this is intended to be an accurate reflection of the current job, management reserves the right to revise the job or to require that other or different tasks be performed as assigned.
Qualifications:

• Bachelors degree in a technical field/business required
• 3+years experience in a Management role
• Operational Excellence program leadership, management or development experience.
• Direct management of professionals to achieve local and national objectives.
• A proven record of accomplishments in continuous improvement events/projects, team leadership and problem-solving, demonstrated success initiating change and influencing at all levels.
• Strong coaching experience, extensive application of Operational Excellence methods and tools.
• Strong technical and management skills in materials and inventory management, production scheduling and preventative maintenance.
• Ability to hire and retain required personnel
• Consistent with business growth build out a team capable of delivering world class, continuous improvement, solid production and facility management success.
• Must be a team player, willing to work in a fast-paced environment and do whatever it takes to get the job done
• Excellent interpersonal and communication skills (oral and written)
• Excellent project and program management skills
• Proficient in MS Office, SAP, 5S

PHYSICAL JOB REQUIREMENTS:
The physical demands described here represent those that an employee must meet to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Lifting of up to 50 lbs.
• A substantial amount of walking, sitting, standing, bending, stooping, and reaching

SAFETY:

• Adhere to company safety policies and procedures
• Wear required PPE (personal protective equipment) where needed
• Immediately report any unsafe conditions or other safety-related issues

WORK ENVIRONMENT:
While the work environment characteristics described here represent those an employee encounters while performing the essential functions of this job, they are in no way all-inclusive. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• While performing the duties of this job, the employee regularly works on equipment on the production floor
• The employee often works at a desk or on other equipment.
• The noise level in the work environment is typically minimal.

Salary Description