Plant Director

OverviewPlant 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 SVP of OperationsRequirementsOperational 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.Required expectations/metrics:I. Production RequirementsUptime is 100%Production lines start on time, breaks start/end on time, lines run until shift ends and with minimal downtimeDowntime must be measured on all lines every day to establish measurement markers based on nature of workSystemic capture of pallets per man hour put-away, etcStanding Planning Meeting/Reporting: Detailed focused effort on planning regarding contingencies when insufficient labor or unavailable WIP and customer product occursii. Line Lead meetingsDaily – Attend and ensure meetings are occurring and discussing previous day performance, along with outlining expectations for todayWeekly – Host, hour long Line Lead meeting off of the production floor, focused on line lead developmentImplement Line Lead Scorecard to capture data and trends for communicating required changesiii. Department stand-Up MeetingsAttend a different start-up meeting every dayGemba Walks: daily, provide findings and report updatesIv. Operating EfficienciesMinimum 100% target Operating Efficiencies (OE) at all times, within first 30 mins of production startupSafety: OIR Vi. Inventory RequirementsReconciliation of all transactional bins in WMS DailyDaily Cycle Count and reconciliation, completed before leaving each nightRoot cause of inventory discrepancies identified and communicated, completed prior to leaving each nightProduction Returns completed daily, if applicableImplement Project Plan for wall-to-wall (PI), in conjunction with finance department and manage process efficiently and effectively as needed – 99.9% accuracy requiredVii. Warehouse/Shipping/ReceivingAnalysis and near-term options developed for dock housekeepingDock is clear physically & systematically by end of shift every nightInventory accuracyAll shipping & receiving discrepancies are resolved by end of dayMaintain warehouse safety (leaning pallets, speed of forklifts, degrading pallets)Visual Factory (5S)Develop basic metricsEstablish and monitor receiving ratesMetrics to be communicated to planningViii. Account ManagementOperational Silence: Identify and eliminate any potential customer noiseBe the Customer: Ensure customer reporting is completed, accurate and timelyRespond to all customer requests and inquiries, same day, with informative and appropriate responsesHero Cards – reported dailyReporting: Production matrix, Daily Activity Report, Shipping reports, etc.Cost Recovery: Ensure all cost recovery opportunities are captured, approved and documented8% monthly minimum invoicedInvoicing: Ensure all invoicing is completed, accurate and timely, must be completed dailyAttend all customer meetings, conference calls, and requested eventsEnsure requirements (conference numbers, GoTo meeting links, reports, presentations, food requirements, agenda, attendees overviews) are staged and ready for meeting startDirect, develop, manage and maintain reporting requirements for all customer information (dashboard formats, or proper reporting structure)Cross-check all billing activities to ensure accuracy and inclusion and submit dailyEmail all customer feedback (positive & negative) to corporateUp to date dashboard reports for internal and customer reporting requirementsCost ControlWith full P&L responsibility, manage all facility costs. Controllable costs include, but aren’t limited to, staff, labor, supplies, maintenance, materials, contracted support, utilities, etc.Manage, maintain and approve all purchase orders, receiving and invoicing documents to efficiently process costs from beginning to endManage all vendor activity within the facility, ensuring accurate time management and records are maintained and audited for invoice processing and reporting requirementsMaintain and management monthly expense reports, along with associated receipts to report accurate financial informationManage, maintain and audit staffing and FTE hours to control costsLabor reconciled daily and reports provided to agencies weekly for invoicingQuality AssurancePlant Director ensures all products meet or exceed customer requirements and that all data is accurate and timely, with support from the quality department.Facility ManagementThe Plant Director maintains building and equipment in good condition and ensures compliance with internal, customer, and 3rd party standards, including pest control, cGMPs, security, and safety.Security Management ResponsibilitiesPerimeter security walksManagement Coverage: ensure management is onsite during operating hoursAlarm Management: ensure restricted access and contact list for emergenciesDevelop, manage and monitor security procedures and building safetyBuilding and equipment costs and maintenance requirementsPM Management of all equipmentAudit SuccessEnsure facilities exceed standards on internal and third-party audits.New Business SolutionsDesign and communicate operating models and costing for new business opportunities and coordinate with sales or customers as needed.Human ResourcesRecruit, train and manage a flexible workforce including permanent, part-time, seasonal, contractors, and temporary staff; manage personnel requirements and performance reviews; build cross-functional bench strength.Final approval of direct report timecards in payrollCustomer Relationship ManagementPlant Director is responsible for the customer relationship from operations and sales perspectives and interfaces with potential customers at events and tours.Disclaimer: This is not necessarily an exhaustive list of responsibilities. Management reserves the right to revise the job or require other tasks.QualificationsBachelors degree in a technical field/business required10-15 years’+ experience in a Management roleOperational Excellence program leadership, management or development experienceDirect management of professionals to achieve local and national objectivesRecord of continuous improvement projects, team leadership and problem-solvingStrong coaching in Operational Excellence methods and toolsStrong skills in materials and inventory management, production scheduling and preventative maintenanceAbility to hire and retain personnelAbility to build a world-class team aligned with company growthTeam player with ability to work in a fast-paced environmentExcellent interpersonal and communication skillsExcellent project and program management skillsProficient in MS Office, SAP, 5SPhysical Job RequirementsLifting up to 50 lbsWalking, standing, bending, and reachingSafetyAdhere to safety policies and wear required PPEReport unsafe conditionsWork EnvironmentProduction floor work; desk workTypical noise level is minimalDisclaimer text removed for clarity and brevity as part of refinement. #J-18808-Ljbffr

Created: 2025-10-06