Operational Excellence Manager

Description Overview

The Senior Operational Excellence Manager will be responsible for driving operational improvement projects as well as working on cross-functional teams to commercialize innovative products in the factory. Continuous improvement and Training efforts will focus on making sustainable gains in reliability, quality, safety, cost, and delivery. The team member will need to collaborate closely with division, factory, and other internal partners to achieve the project objectives aligned with the business needs. The team member will be responsible to carry out assignments of a broad nature while exercising considerable judgment and creativity. The team member needs to be able to carry out appropriate financial investigation to validate/support proposals and gain support of key stakeholders.  This position directly reports to Plant Director, and indirectly reports to Associate Director of PWS/Training.  Plant PWS Lead and Plant Training teams will report this role. 

Scope of the Role

• Drive Continuous Improvement & Productivity Savings Projects 
  • Be a champion for continuous improvement in the factory. Act as a change agent.  Continuous improvement is about changing the culture. Coach employees using the GROW method for coaching.
  • Identify and guide significant improvement initiatives by developing Long Term Continuous Improvement Plan.  Utilize Continuous Excellence tools and methodologies (Goal Alignment, GSTD, DMAIC, Loss Tree Analysis, IPA, etc.) to drive sustainable operational improvements. Analyze given data and operating conditions; implement changes and follow-up on results by involving key responsible people (i.e. sponsor, process owner, and operator).
  • Develop and train production associates with GI, NSAT, Performance Indicators, and target cost savings to understand and achieve continuous improvement of factory performance.
  • Ensure incorporation of the Continuous Improvement Plan in factory OMP. Implement controls to ensure results are sustainable; i.e. Standards (CILs, center lining, visual management, SOPs, startup/shutdown checklists, etc), Deliver and document training of effected employees, Mistake Proofing.
  • Provide project updates to the factory management team and project stakeholders highlighting the current status, adherence to the project time plan, work accomplished, quick wins, points of escalation, elements of risk and the associated mitigation plans.
  • Determine means to reduce material usages, material losses and rework, and to achieve energy savings.
  • Carry out follow-up programs to maintain the achieved savings, to complete additional training, to detect further savings opportunities, as well as ensure the overall continuity of the project.
  • Support budget preparation activities and maintain other Operational performance related Factory data systems (CST).
• Operations Support through PWS Lead
  • Routine Review of Line Performances and Factory KPIs
  • Conduct capacity studies, when needed.
  • Understand the SHO to DOR communication cycle and be able to coach others on that cycle.
  • Attend Daily Operations Review (DOR). Use Basic Problem-Solving methodology to solve daily issues prioritized in DOR.  Coach employees on completing Basic Problem-Solving activities.
  • Interact with machine operators and mechanics with respect to problem solving and SHO measures, issues, and actions.
  • Conduct training and coaching for DMO and SAP systems, for production personnel.
• Drive Training Program Management, Development and Compliance through Sr. Training Program Supervisor. 
  • Training Program Development:
    •  Identify training needs across different operational departments.
    • Develop comprehensive training programs to address identified needs.
    • Create training materials, including manuals, presentations, and online resources.
    • Collaborate with subject matter experts to ensure accuracy and relevance of training content.
    • Implement effective training delivery methods, including instructor-led classes, workshops, and e-learning modules. 
• Compliance 
  • Manage SAM master data and set up.  Assure SAM alignment with SAP to preserve integrity of both systems.  Perform periodic SAM data and entry health checks to help ensure data integrity.
  • Maintain SOPs/Work Instructions for SAM tracking and IP functions
  • Perform annual nominal rate studies for the factory to meet GI compliance.

Experience Required

• Bachelor of Science degree in Industrial Engineering, Engineering or Business
• Required: At least 5 -7 years in plant /manufacturing environment, including minimum of 2 years work experience with continuous improvement, Industrial Performance, TPM, or related programs and with examples of application of results.  Implementation experience with TPM or Lean Value Stream is strongly preferred. Experience in an FDA setting preferred.
• Minimum of 2 years working & developing improvement projects, loss analysis, & strong experience in leading /applying problem solving tools with active role in the implementation of Goal Alignment/TPM/Lean Manufacturing.
• Experience working with Line labor standards, Budget preparation/review, and line capability/speed studies.