GE Appliances, a Haier company Senior Manager, Manufacturing Operations in Columbia, South Carolina
USA, Columbia, SC
Job Posting Title
Senior Manager, Manufacturing Operations
As the Senior Manager, Manufacturing Operations you'll be directly responsible for leadership of the Operations team (consisting of direct report salaried resources and indirect hourly team members), while promoting, steering and instilling the Appliance Production System (APS) methodologies to affect continuous improvement across the major operational facets of Safety, Quality, Productivity and Cost in a high volume, fast paced manufacturing environment.
Short term, you'll be the primary person representing the Manufacturing and Operations function with the Water Heater NPI Program. This short-term representation will run for the majority of 2020 with the focus shifting to production operations at NPI launch. Significant business travel to support the Water Heater NPI Program will be required during 2020.
What you will Do
Own and prepare the annual operational plan/playbook for a manufacturing value stream. Responsible for operational performance and improvement of key metrics including safety, quality, delivery, cost and culture. Align area metrics with overall plant goals; organize resources to deliver on these metrics.
Steer activities of cross-functional manufacturing team, to include responsibility for salaried and hourly team members within the assigned business unit.
Direct Reports include Area Business Leader (ABL) and Process Improvement Engineer (PIE)
Indirect Reports: Team Leader (TL)
Utilize production line boards to collect information on value stream performance, issue identification and problem resolution. Ensure information is passed on to the following shift and management. Hold team accountable to maintain and manage the boards.
Maintain a good technical knowledge of operations; follow the escalation process to address and respond to abnormalities and recommend corrective action as required.
Ensure the Lean manufacturing practices and Escalation Process set forth under the Appliance Production System are followed and adhered to within the value stream manufacturing operations.
Manage and track all department metrics and budget. Prepare daily report-out of metrics for production meeting.
Establish daily operating rhythm in department. Conduct daily start up meeting with TL's and ABL's. Maintain rigor around daily team manager meetings, escalation meetings, etc.
Prepare topics for daily team meetings; ensure team leadersunderstand and cascade the message appropriately and correctly. Rotate through the team meetings each day.
Oversee the deployment of standardized work within the value stream operation. Ensure process stability through following standardized work.
Coach and develop Area Business Leaders, Process Improvement Engineers and Team Leaders to ensure standardized work is in place and is followed.
Ensure adherence to Job Instruction method by reviewing and verifying Job Instruction forms, including cross training matrix, and Team Leader delivery of four step method to ensure ‘Critical Points’ and ‘Why’ are conveyed accurately and effectively.
Ensure 5S standards are met for the entire value stream.
What you need to Succeed
CONTINUOUS IMPROVEMENT: Live, promote and teach the Appliance Production System philosophy and steer continuous improvement within the value stream operation.
Manage and promote work team(s) that react proactively to factory inefficiencies. Guide problem-solving and root cause identification of problems for the entire value stream.
Engage all members of cross-functional escalation team to address and resolve problems, ex. Area Business Leaders, Team Leaders, Kaizen Promotion Officers and other Lean resources
Continuously identify and work to reduce waste in the area for both short term and long-term improvement initiatives.
Serve as a second-level responder within the escalation process for problems/issues within the value stream operation.
Manage regular meetings to review department issues. Prioritize and assign ownership for open items. Track items to closure and ensure follow-up with key stakeholders.
Promote kaizen events within department. Ensure related countermeasures are implemented on manufacturing line(s).
Oversee the planning and execution of work area re-balancing utilizing Yamasaki charts.
LEADERSHIP. Provide effective day-to-day leadership for a highly energized, integrated, cross-functional manufacturing team.
Create goals for each member of the team. Ensure one-on-one career coaching, performance feedback, employee training and talent development. Participate in the annual performance review process.
Manage employee disciplinary investigation and action as appropriate. Partner with HR to conduct timely investigations when necessary. Complete accurate and thorough disciplinary records with supporting documentation.
Recruit resources to fill team needs in a timely fashion.
Develop and mentor future managers for the business.
Partner with site Human Resources team to ensure fair and consistent administration of all policies, work rules and processes.
QUALITY: Ensure the products produced within the entire value stream operation are defect-free and produced according to specifications.
Ensure Manufacturing Control Plan (MCP) and all quality processes/standards are followed within entire value stream.
Monitor manufacturing processes, data & reports daily and deliver the resolution or escalation for any defect.
Ensure Team Leaders and PIE’s include quality standards in Standardized Work to meet design intent and build in quality.
Work cross-functionally with multiple stakeholders to address and solve production line quality issues (i.e. Team Leader, engineering, quality).
Monitor scrap data/reports to deliver resolution of scrap issues and work projects to prevent future scrap.
Partner with Plant Quality staff and engineering to steer improvements in key quality metrics, including First Pass Yield, Overall Yield and Service Call Rate (SCR) metrics.
SAFETY: Responsible for the overall safety performance and metrics for the value stream operation.
Promote a sound safety-minded culture in the value stream. Maintain an effective safety program, ensuring the observation of safety precautions and safe work methods by all personnel, including behavior-based safety observations, safety meetings, safety audits and 5S housekeeping standards.
Enforce compliance to safety rules and procedures, timely accident investigations, Safety Contacts and Safe Start participation.
Review and sign off on all accident investigations. Ensure they are completed in a timely manner and identify root cause and corrective action to deliver required changes.
Manage the department's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.
Bachelor’s degree with technical degree preferred
5 years' minimum experience in progressive manufacturing leadership roles.
5 years' minimum of operations management and planning experience.
5 years' minimum of hands on experience in manufacturing equipment.
Technical or Engineering degree preferred
Program Graduate (OMLP, EEDP).
Six Sigma Green Belt certification or higher.
Working knowledge of Toyota Production System: JIT, JIDOKA and HEIJUNKA.
Experience with tools such as SMED, 5S’s, POKA-YOKE, KAN BAN and CHAKU-CHAU.
Significant experience in implementing Lean process improvements in manufacturing operations.
GE Appliances does not offer sponsorship for this position
GE Appliances is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.