Senior Manager, Manufacturing

Compensation: $,-, plus $15, target bonus, up to %
Job Summary:

The Senior Manager Manufacturing is responsible for leading the cardbody manufacturing area and for the efficient operation of the complete Card Manufacturing department, including Press Room, covering litho and silk screen production as well as the Pre-press / Graphics team, and the complete Card Finishing area. Key to this role is the ability to work closely with the Product Management, Sales and Customer Service teams in forming a collaborative relationship with our customers to provide support and guidance in the design, development and implementation of of new card designs and products. This role is also responsible to oversee the efficient execution of the production schedule and all related activities for the achievement of department KPIs. With that in mind, it is expected that the Manager will work to identify, implement and ensure compliance with standard work procedures relating to production processes that ensure the timeliness and quality of production work and compliance with all security and safety standards. The mandate is to develop and drive a flexible best in-class manufacturing environment producing a high quality product at a competitive price with % on time delivery. Through best practice sharing, collaboration and application of Lean principles, the Sr. Manager Manufacturing will apply their expertise to direct and guide team members toward operational excellence throughout the manufacturing environment.

Responsibilities:

• Sponsor the necessary changes for improvement in manufacturing processes, procedures and production flow, always in line with Lean Manufacturing aspects, in order to provide the correct physical and technical production environment.
• Guarantee production schedule attainment, constantly interacting with the Scheduling Team to share knowledge and advice, supporting our planning and scheduling accuracy.
• Ensure the Quality of our products, guaranteeing that our manufacturing line follows all Quality control plans in all shifts.
• Leads, Manages and Coordinates all day to day activities and resources in the Card Manufacturing Production processes and production output in accordance with Industry and Company standards.
• Ensures department KPIs are being met (On time and complete / productivity throughputs / quality / scrap rates) .
• Ensures compliance with all production, quality and security standards and updates departmental procedures and guidelines as necessary.
• Ensure that effective communication is maintained with all departments and teams necessary for the smooth operation of the Press Room.
• Manages all staffing related activities in collaboration with Human Resources.
• Ensure proper health & safety, and security procedures are adhered to by all staff.
• Assist in developing, executing, and supporting Lean initiatives for the department.
• Ensure a proper investigation is performed, and solutions provided for, any Non-conformance Reports assigned to the department.
• Provides collaboration and input for, and maintains, the approved Press Room budget and subsequent forecasts providing reports and solutions on significant budget variances as required.
• Encourages and promotes team work at all levels.
• Support Sales and Product Management in developing new products and client initiatives.
• Ensure the periodic inspection and calibration of equipment being used to ensure accuracy.
• Ensure the Production Schedule is achieved and accurately identifies risks affecting the supply, transformation and delivery of products and services to meet customer demand. Develops strategies to analyze the probability and control the impact of the identified risks.
• Drive and champion new technologies, collaborations, and improved processes to define, leverage, and implement best production practices including leading continuous improvements in cost reduction, production time, and pipeline capacity using methodologies such as Lean Manufacturing principles and detailed analysis of daily/ monthly performance data and root-cause analysis of non-compliance reports (NCR’s) .
• Active member of the SR. Mgmt Team promoting regular communication exchange with colleagues at all levels of the organization to support the Sales and Operational planning processes.
• Interfaces with internal QM and Supply Chain stakeholders concerning topics / issues involving Bill of Materials and equipment.
• Develops, coaches and motivates the Team through technical printing expertise, best practice sharing, skills matrix development and annual staff performance reviews.
• Acts as Technical Print expert / support in Projects and Customer interactions.
• Maintains Industry knowledge on new products (materials), technical print solutions and production processes to improve quality, yields and reduce costs.
• Ensures all manufacturing equipment is maintained and operating at optimal performance.
• Develops and maintains budget and capital expenditures relating to cardbody manufacturing.
• Complies with Environmental, Health & Safety policies, procedures and report any Environmental, Health & Safety hazards, incidents and concerns to Upper Management.
• Other duties as assigned

Accountabilities:

• Deliver High quality of finished goods.
• Meeting production and shipping schedule.
• Compliance with Departmental, Quality and Process guidelines
• Attainment of departmental KPI’s.
• Maintaining and achieving scrap reduction goals.
• Safety & Environmental Compliance
• Workforce training and development
• General management and performance of the department.

Job Specifications:

• Work performed in a light industrial setting.
• Exposure to shop noise.
• Occasionally required to lift up to 30 lbs.
• Regularly required to sit, stand, reach and move about facilities.
• Travel, including international.

Qualifications, Experience and Educational Requirements

Work Experience:

• Minimum 10+ years of progressively responsible experience of management in a manufacturing environment.
• Minimum 10 years of progressively responsible management experience in a commercial printing environment.
• Strong Knowledge of color management, offset printing, ink properties, color matching experience, manufacturing and finishing lines with mechanical and electronical equipment.
• Working knowledge of prepress and workflow software, e.g. Adobe Premium, Macintosh, color management software.
• Significant exposure to aspects of digital film output for the printing process such as trapping, film proofing, image setter and processor maintenance, plate making and quality control.
• Must have solid understanding of business practices in a Manufacturing environment.
• Hands on leadership of a team of 10+ employees for at least 3 years is an asset.
• Lean Manufacturing knowledge and/or experience is an asset.
• Experience in card manufacturing plant a plus.
• Practical knowledge of theory and principles of lean manufacturing.
• Excellent verbal and written communication skills .
• Above average mechanical knowledge of production equipment.
• Proficient in manufacturing scheduling.
• Above average computer skills including word processing, spreadsheets and ERP systems.
• Understanding of general safety requirements.

Skills and Competencies:

• Experience with Lean Manufacturing production environments
• Ability to plan for short, mid and long terms, with focus on details and contingencies
• Manufacturing cost control and P&L analysis
• Knowledge of production scheduling considering complex iterations and precedences for production orders
• Strong communication skills and ability to build direct relationships with associates
• Excellent organizational skills with a high degree of initiative and flexibility
• Capable of working in a diversified, fast paced service bureau environment
• Detailed and quality focused approach to managing
• Litho and Screen printing process experience and knowledge
• Strong computer skills (MS Office, Lotus Notes)

Business Competencies:

• Demonstrates the ability to manage a network of interconnected businesses and processes involved in the provision of products and services.
• Strong understanding of all management activities carried out in the course of running an organization and the disciplines of planning, organizing and managing resources to bring about the successful completion of specific goals and objectives.
• Practices goal-oriented thinking. The process involves the ability to map alternate courses of action, identify associated critical success factors, assess the likely outcomes and consequences of the actions, and chose the best course.
• Capacity to think in careful and discerning ways to solve problems, analyze data and to recall and apply information.
• Understands the systematic approach to closing process and system performance gaps through streamlining, cycle reduction, elimination of quality defects, and reduction of process variation / non value adding activities.
• Demonstrates a commitment to the mission and motivation of a team and understands the dynamics of effective teamwork in order to attain higher levels of performance.

Personal Competencies:

• Demonstrates trustworthiness and professionalism when dealing with clients, peers and team members.
• Understands and anticipates the business needs and concerns of others and shows perspective in other points of view.
• Ability in identifying and managing conflict in a sensible, fair and efficient manner.
• Takes steps to develop and maintain knowledge, skills and expertise to achieve positive results.
• Practices meaningful two way communication and persuasively presents thoughts and ideas, in both written and verbal form, gaining commitment and ensuring support.
• Demonstrates intellectual curiosity about the current environment and challenges the status quo with a bias towards action and continuous improvement.
• Demonstrates the willingness to accept responsibility and accountability.

Education:

• A degree in Engineering, and / or business Management preferred or equivalent work experience in a print production environment.

Working Conditions:

• 7x24 operating production environment
• Fast paced environment with changing priorities based on customer demand and supply chain circumstances
• May be exposed to high levels of noise within production with eye and ear protection required
• Safety shoes and smock required

Physical Requirements:

• Must be able to lift up to 30 lbs.
• Able to stand for long periods of time
• Able to stay for overtime as required