SUMMARY
This role reports to the Director of Operations and will have responsibility for effectively managing the day-to-day Safety, Quality, Throughput, and Cost for the VAR (Vacuum Arc Remelt) business unit and associated raw material supply which includes, but is not limited to, BW (Bulk Weld), CP (Compact Press), and Electrode Preparation Areas. In conjunction with the Director of Operations, the position is responsible for maximizing business unit and plant-wide productivity, quality, and technical skill development to ensure on-time shipments and customer satisfaction, as well as reducing variable costs. The focus of the role will be to execute the daily, weekly, and quarterly plans for the factory; managing the people, assets, and other resources to carry them out in a safe, efficient, and productive manner. This is a pro-active as well as a reactive role which is an integral position in the senior leadership team and is responsible for developing and driving a high performing organization to achieve established goals.
Below is a summary of key focuses in each area:
* Safety - Accountable for Leading the Site's and Regulatory EHS requirements, establishing a collaborative and positive safety culture (both within the business unit and factory-wide) which is focused on leading as well as lagging safety performance indicators, leading incident investigations and driving them to resolution, and possessing a vision and strategy for implementing safety improvements.
* Quality - Accountable for process control, standard work, and reduced variation for the Business Unit. Shall be responsible for implementing a structured manufacturing process which is procedural based and creates a "zero defect" culture.
* Staffing / People - Must actively manage staffing to support the production plan, in addition to tracking, reporting, and achieving other metrics such as: overtime rate, absentee rate, productivity goals, and other staffing / HR metrics as defined.
* Continuous Improvement - Responsible for leading a continuous improvement culture by setting expectations for 6S, integration of lean manufacturing principles, and developing and actively managing continuous improvement pipeline projects. Will work closely with the Continuous Improvement Manager for the site to achieve factory-wide initiative and goals.
* Production / Throughput - Accountable for accomplishing TOC production targets (Theory of Constraints) as scheduled in the production plan, as well as developing and adhering to recovery plans to get back to target if an interruption occurs.
* Scheduling - Must develop and drive adherence to daily work plans to optimize the performance of the site. Plans must be well-communicated with expectations clearly defined.
* P&L Responsibility - Accountable for managing the P&L, primarily variable costs, of the VAR business unit. Must achieve or exceed goals set forth in the daily cost targets which ultimately enables the site to meet quarterly financial goals. Must develop and adhere to financial recovery plans to get back on track if a deviation from the spending plan occurs.
* Engagement / Leadership - This position requires an active leadership style with a daily presence on the factory floor engaging with people and processes. Must be visible and available. Responsible for leading daily metric reviews (Line Walks) with the team in the business unit and present Safety, Quality, Throughput, and Cost results to the Director of Operations and General Manager. Must also establish a cadence of effective shift handover meetings to set expectations for each shift and communicate the strategy to the team.
ESSENTIAL FUNCTIONS
* Is responsible for establishing and delivering the EHS & Productivity targets for the business unit for each quarter based on sales Budget, ESH and staffing model to set headcount levels and productivity targets.
* Is responsible for capacity modeling for the business unit to identify bottlenecks/ constraints with appropriate plans and work with the continuous improvement and technical teams to ensure sufficient capacity to support the budget.
* EHS Initiatives:
o Will represent the VAR Business Unit in executive EHS meetings and will be accountable for action close out.
o Will develop a process to communicate and manage the implementation of all new EHS initiatives and will be responsible for ongoing monitoring and compliance.
o Will be accountable for all EHS and 6S audits within the business unit in collaboration with the EHS and Continuous Improvement departments.
* Is accountable for leading a fully engaged work force environment such as soliciting, reviewing, and implementing suggestions for improvement within the business unit.
* Will represent the VAR business unit in pipeline and yield meeting and be accountable for updates and progress reporting on all production related cost saving projects.
* Is responsible for the management of Excess & Obsolete (E&O) material in WIP to achieve quarter budget.
* Will be accountable for leading, motivating and engaging with subordinate leadership team through effective communication e.g. team briefings, regular interaction on the factory floor, involvement of team in projects and initiatives.
* Will be responsible for the management of Operations Supervisors / leaders within the business unit to include objective setting, performance reviews, absence management.
* Is accountable for ensuring the daily TOC and flex targets are achieved in line with the production plan
* Will lead the production team to establish priorities relating to site requirements, communicating with supporting departments and other business units to ensure business needs are met site-wide.
* Is responsible for reviewing existing systems and identifying improvements for internal and external quality, cost and on-time delivery to the customer requirements.
* Accountable for setting the variable labor cost plan for the business unit and working with production team to determine required staffing levels and support labor re-allocation across the site as required.
* Is responsible for all aspects of recruiting and training employees within the business unit, including but not limited to: planning, assigning and directing work, evaluating and appraising individual performance, rewarding and disciplining employees, and addressing complaints and resolving problems.
* Is accountable for flexibility of the workforce to address skills gaps which must be overcome to create an adaptable workforce. Will be responsible for analyzing training needs, developing and executing training programs, and tracking team member training and qualification records.
* Will control departmental budget through the daily flex (daily departmental and site-wide cost report) and management of outwork.
* Will drive the production team to use process Improvement and Lean Manufacturing Tools such as SPC, FMEAs, 6S and Lean Sigma structured problem-solving techniques to drive improvements. Decisions and discussions must be data driven to effectively drive the business.
* Will commit to using tools within the PCC Toolbox to manage business activities and develop leadership team to incorporate these tools in the daily culture.
* Will be an area owner for 6S and attend weekly meetings to communicate updates to the Senior / Executive management teams.
* Is accountable for ensuring that the VAR business unit works closely with the Maintenance and Engineering Department and adheres to the preventative and predictive maintenance plans and strategies established for the site. Will be co-responsible for ensuring that all maintenance KPI's are met for the business unit. (the site Maintenance and Engineering Manager will be the counterpart)
* Ensure compliance with LOTO standards within the business unit.
* Will work closely with production and raw materials planning to develop and execute operational strategy and daily melt plans, raw materials movements, maximize production velocity, and reduce inventory. Routinely engages with Purchasing and Logistics to manage raw material supply, assist with maintenance and repair material inventory and procurement, and manage shipments to internal and external customers.
* Will work with Human Resources to develop a positive business unit culture which is high-performing and engaging, while adhering to core values established for the site.
* Accountable for adhering to all Sarbanes Oxley (SOX) requirements and other financial policies and guidelines for the site. The Business Unit Manager shall set this tone for his / her team and ensure that all requirements are followed.
* Will present all business unit metrics to the Director of Operations and / or the General Manager on at least a weekly basis and will update plans and strategy to ensure alignment with the overall goals of the site.
* Must be committed to continuous learning and evaluating / adopting new practices and strategies to improve the business unit.
* Must be willing to cross-train with other business unit managers on-site and be involved in other departments to understand all aspects of the business.
* Other duties as assigned.
KNOWLEDGE/QUALIFICATION/EDUCATION
* Bachelor's Degree in Mechanical, Electrical, or related Engineering Discipline.
* MBA in Business Administration (Not required, but is a plus)
* Formal training in Lean, Six Sigma, and Continuous Improvement.
* A background in a metals manufacturing or a melt shop is preferred, but not required.
* Able to interpret high level business objectives into day-to-day plans and roll out and delegate to teams, able to clearly identify day-to-day priorities, and create action plans to deliver.
* Demonstrable computer skills including: Microsoft Windows, Microsoft Office 365, ERP Software, MES Automation and Production Execution Software, interfacing with SCADA systems, etc.
EXPERIENCE
* Minimum of 5 years of experience in a similar role in an industrial manufacturing environment, preferably a business services the aerospace, automotive, or energy markets.
* Proven track record of career progression throughout a manufacturing environment with a minimum of 10 years of overall applicable industry experience.
* Background in maintenance and engineering is strongly preferred.
* Minimum of 5 years of experience in managing people (development and managing performance), managing information (effective budget control and communication activities), managing activities (prioritizing activities, continuous improvement activities) and managing systems such as OSHA and ISO.
ADDITIONAL SKILLS
* Must be able to demonstrate a range of leadership skills such as delegation, coaching and support while being able to interpret and challenge traditional behaviors and practices.
* Will be an effective leader and act in a manner that maintains a positive and productive work environment with customers, clients, co-workers and supervisors.
* Good written and verbal communication skills, with the ability to communicate effectively at all levels are essential
* Working knowledge of Continuous improvements methodology and appropriate coaching and teaching skills are an advantage.
* A willingness to be trained to a minimum of a Green Belt standard in Lean Six sigma
BEHAVIOURAL COMPETENCIES
* Positive CAN DO ATTITUDE.
* Strong sense of urgency.
* Right to Left Thinking - Begin with the end in mind - what do you want the end result to be?
* In FRONT of every good team is a good leader.
* Provide the team with resources to improve.
* No Limits to improvement (don't be bound by 2% QoQ) - no end.
* Become a noted authority; both operational and technically.
* High energy level and able to work flexible hours.
* Solid business acumen.
* Strong mindset for continuous improvement.
* Able to motivate and develop teams to meet performance requirements.
* Represents TIMET well throughout the community.
PHYSICAL DIMENSIONS PHYSICAL DEMANDS
Position requires applicant to be engaged in the factory on a daily basis. This includes, but is not limited to: walking throughout the various departments, assisting maintenance with troubleshooting and repairing equipment, ability to inspect overhead cranes and work at heights, lift up to 35 lbs, and other physical job tasks as required.
WORK ENVIRONMENT
Position requires applicant to safely and responsibly work in an industrial environment with overhead cranes, specialized furnaces, mobile equipment, and various other manufacturing equipment as required for business
Precision Castparts Corp. (PCC)
Apr 11, 2025