JOB SUMMARY

Manages all print and assembly manufacturing operations for the Harmar Street Plant, the Plate Lab and Ink Room and Production Engineering department.

DUTIES AND RESPONSIBILITIES

 
1. Management & Administration - responsible for the overall management of the Printing, Welding, Assembly, Plate Lab, Ink Room and production Engineering departments including a) setting goals and objectives that contribute to the attainment of overall business strategies, b) leading and supervising a Team of managerial, supervisory and manufacturing personnel preparing plates and screens used in decoration, mixing inks, decorating and assembling injection molded and blow molded plastic component parts and other purchased products, and otherwise functionally meet the requirements of business operations, c) budget management, d) development, implementation and administration of suitable, adequate and effective business management systems and procedures, e) performance of required administrative tasks, and f) following generally accepted professional methods and practices applied in the context of continuous improvement.  Representative duties may include:
      

• Alignment of functional strategies and objectives with overall business strategies
• Development and management of functional performance plans to successful conclusion
• Serving as functional advocate and representative at staff/business meetings
• Establishing and maintaining effective intra- and inter-departmental communication processes
• Development and management of the functional budget
• Ensuring functional activities are managed safely, efficiently, productively and in compliance with all applicable laws, regulations, and company policies
• Record-keeping
• Securing the necessary equipment/materials/supplies needed to fulfill functional responsibilities
• Administration and enforcement of company policies and procedures
• Development of functional policies, procedures, reports, and other documents

 
2. Supervision - responsible for staffing, managing and supervising the performance of a Team of managerial, supervisory and manufacturing personnel to ensure that team goals and objectives are achieved by ensuring TeamMate job core responsibilities and performance expectations are well defined, TeamMates have a clear understanding of department goals and objectives, TeamMates have the necessary skills, tools and materials to do their job, and the general working climate facilitates the successful performance of their job responsibilities.  Representive duties include:
 

• Interviewing candidates and staffing position vacancies in a timely basis with qualified people capable of meeting the requirements of the position
• Develops and manages work schedules
• Schedules and prioritizes work
• Assigns and monitors work ensuring it is completed in an efficient, cost-effective fashion 
• Manages and evaluates performance
• Identifies and addresses training & development needs
• Coaches, counsels, and resolves complaints
• Ensures compliance with company policies & procedures

 

3. Production & Management of Production Resources – responsible for development and implementation of sound manufacturing processes and for ensuring preventative maintenance is completed on department equipment, inventory, staffing, manufacturing execution, shop floor reporting and internal control systems to ensure on-time delivery of manufactured products and reporting of production results in an accurate and fair manner.  Representive duties include:
 

• Plans for and designs manufacturing processes, determines manufacturing capacities

• Delineates preferred methods of manufacture and utilization of production facilities and personnel to maximize utilization of equipment and efficiency of operations
  • Ensure there is a preventative maintenance system and an inventory of common wear parts for equipment and equipment is regularly serviced
  • Addresses Machine Trouble reports with Shift Manager and Production Maintenance Supervisor and follows-up to see that maintenance is completed as promised or planned
  • Establishes operating procedures, training programs and implements other needed measures to ensure proper use, maintenance and care of buildings, machinery and equipment under the manager’s control
  • Ensures equipment is regularly serviced
  • Oversees all equipment adjustments and ensures all Order Processing Concerns and/or Machine Trouble Reports are completed as accurately as possible for a minimal amount of downtime
  • Evaluates new equipment, techniques and technologies and submits proposals and recommendations
  • Meets with the Facilities Manager on a weekly basis to discuss maintenance projects and concerns
  • Enforces manufacturing standards established by the Industrial Engineer and requests review of same, when necessary
  • Makes staffing decisions and manages labor resources based on changes in the production activity level.  At the Harmer Street Plant, work can be sent to the workshops or more work brought in-house. High School workers are employed from 4 PM to 8:30 PM on second shift Monday to Friday.  Temporary service help is available as our busy season begins and until such time as college students are available for summer employment and high school students are available to work full-time hours.    Voluntary layoffs, slo-time and/or transferring TeamMates to other departments must be used for extended slow periods. As a matter of practice before slo-time is authorized, the Mold Plant Manager or Mold Team Shift Manager should be consulted to see if additional help is needed.
  • Runs and reviews Capacity Planning reports CAP20ICL, CAP202CL, CAP203CL and CAP204CL (See option #’s 1 to 4 on the MRP/Capacity Reports menu which is option #14 on the Main Menu Production) each week to ensure we have machine and man capacity to produce scheduled/planned orders.  Communicates issues/concerns and takes appropriate actions with respect to machine utilization and staffing.
  • Runs and reviews the Scheduled Orders Priority Report (see option #10 on the MRP/Capacity Reports Menu which is option #14 on the Main Menu Production) each day to ensure orders are on track for on-time completion at Harmer.  The complete by dates must be met to ensure workshops have adequate time to process orders (as applicable) and to ensure on time shipment.
  • Works closely with the Master Scheduler/Order Expeditor to facilitate timely scheduling and completion of customer orders
  • Posts voluntary overtime and/or mandates overtime assignments to achieve Company order level
  • Manages inventory levels for indirect materials based on the production activity level with consideration also given to supplier lead times, price movement and pricing trends
  • Monitors execution of Kanban System for work cell inbound and outbound squares
  • Investigates or reviews recommendations pertaining to new developments in materials and supplies, and directs the testing of new plates, inks, blankets, and other printing supplies
  • Participates in bi-weekly Production Team meetings where production needs are discussed and Mold production schedules are planned
  • Participates in Harmer Improvement bi-weekly meeting
  • Follows a disciplined approach to production planning while allowing the flexibility needed to meet customer requirements as special situations arise
  • Directs all manufacturing activities
  • Monitors progress of set-ups, maintenance activities and actual versus planned production quantities
  • Reviews daily order processing concerns written and quality errors.  Directs investigation (root cause analysis) and corrective/preventive actions.
  • Works with Engineering, Quality, Production Engineering and Mold to address product non-conformances and identify and implement corrective actions
  • Develops and implements plans to resolve staffing, materials and operational issues
  • Meets regularly with Shift Managers
• Identifies process and other continuous improvement opportunities, including equipment change-over and product set-up
• Establishes standard procedures and controls needed for accurate recording of inventory and production transactions
• Initiate and carry out programs to enforce standard operating and standard reporting system procedures and disciplines
• Reviews activity, operating and production reports to determine required changes in operations
• Analyzes and reports on operation methods, processes, equipment and facilities in light of current operational needs and anticipated future needs
• Participates in the development of a planning, scheduling, material and capacity requirements planning system

 
 
4.   Budgeting, Purchasing, Cost & Productivity Management – responsible for capital and expense budgets for
department; purchase of operating supplies; cost control and maximizing productivity (man, machine, methods, materials) to contribute to a high level of profitability for the company.  Representive duties include:
 

• Completes engineering economy studies to determine costs and savings associated with a given project or proposal so that discounted cost flow analyses, lease-buy analyses can be run to calculate rates of return, payback, cost savings, etc. 
• Submission of capital expenditure requests for department(s) managed, review and approval with the Executive Team
• Develops plans to accomplish introduction of new equipment and/or modifications to or rearrangement of existing equipment or work areas in an effective manner with minimal impact on production
• Preparation of an annual operating budget for department(s) managed
• Discretionary spending request review
• Ensures appropriate details and specifications are provided on equipment purchase orders
• Ensures materials and supplies are purchased at the best possible price after taking Company requirements for quality, delivery and service into consideration and in accordance with company policy and Purchase Committee procedure
• Performs audits and prepares reports addressing actual versus projected results in terms of objectives, project cost and operational results/savings
  • Development, analysis and interpretation of information and preparation of confidential reports, analyses and other specialized management information to appraise results in terms of costs, budgets, policies of operations, trends and increased profit opportunities
  • Determines root cause of scrap and implements corrective action steps necessary to address:
    • Post decoration rejects greater than 1% of order total
    • An operation based reject rate by product group greater than 1%
    • An order specific reject rate greater than 1.5%
  • Reviews material usage, alternate operation, scrap, alternate location and direct labor manufacturing variances to ensure scanning accuracy (operation numbers, total pieces produced, scrap pieces produced), bill of material accuracy and scrap reporting accuracy for orders being processed.  Identifies and resolves problems.
  • Monitors shift productivity, efficiency, and utilization logs and follows-up with any problems; suggests solutions.  Drives direct labor utilization by monitoring the time spent by direct labor TeamMates on indirect labor work.
  • Performs or schedules a review of operations that report a monthly efficiency of less than 75% and implements new processes to improve this efficiency
  • Reviews all labor heavy work cells and develops approaches to reduce total labor requirements by realignment of job tasks, automation or other means

• Makes or acts on recommendations to reduce cost and improve quality
• Identification and implementation of process improvements and cost reduction opportunities

• Focuses on continuous improvement of equipment and processes
• Participates in systems development and administration and the development of performance measurements

 
5.Quality – responsible for ensuring the quality integrity of delivered products and instilling a zero defects
culture for departments managed.  Representive duties include:
 

• Works with Management and the Quality Engineering Manager to establish quality control standards, programs and procedures
• Ensures that all quality programs and procedures that Management has developed and agreed to are implemented, enforced and adhered to in order to achieve continuous production of products consistent with established standards
• Establishes plans for the attainment of quality goals
• Ensures that TeamMates have been trained, developed and involved in quality activities and for all tasks relevant to performing their job, including but not limited to, Quality Control procedures, inspection techniques, and problem notification and documentation
• Ensures products are decorated and assembled correctly and are of high quality for customer satisfaction. Maintains high quality standards by enforcing quality procedures that will eliminate down-stream rejects/scrap and avoid Company losses from returned orders, reprinting and customer dissatisfaction. 
• Cooperates in the investigation of customer complaints so that root causes can be determined and eliminated
• Participates in and provides feedback on quality improvement and corrective action projects

 
 
6.   Safety & Housekeeping – responsible for maintaining a safe and healthy work environment with zero
workplace incidents due to unsafe acts and unsafe conditions and no lost time incidents.  Representive duties include:
 

• Oversees administration and enforcement of policies and safety regulations to established practices and promotes excellent TeamMate relations
• Ensures that all safety programs developed by the Safety Coordinator and Safety Steering Committee are implemented, enforced and adhered to by all TeamMates
• Ensures that all operations are performed with the utmost regard for the safety and health of all personnel involved
• Ensures that all equipment utilized in the Plant is free of recognized hazards and that all TeamMates have been trained in the safe and proper use of the equipment
• Ensures that Safety Talks are conducted when required and attendance is documented
• Makes housekeeping a day-to-day practice by ensuring that the guidelines for “Manufacturers of Food Packaging” are followed as a matter of routine. Internal inspections should result in few, if any, corrective actions. Corrective actions must be addressed in a timely fashion and not repeat in subsequent Whirley inspections.
• Ensures that all incidents in the Plant are investigated thoroughly, hazards and unsafe conditions are eliminated, and unsafe acts are discussed promptly with appropriate discipline issued
• Meets weekly with Safety and Environmental Coordinator to discuss safety issues; ensures safety procedures are in place and adhered to

• Participates in the monthly Safety Committee Meeting

 
 
7.   Production Engineering - responsible for design and build or purchase of decoration and assembly equipment, auxiliary equipment and production tooling and maintenance of production equipment in a safe and timely manner following generally accepted professional methods and practices and complying with all laws and regulations to ensure safe, reliable cost-effective operation and maximum productivity.  Representive duties include:  
 

• Manages production engineering projects involving new equipment and processes as well as replacement or modification of existing equipment and processes
• Plans and prepares for the design transfer of new products from R&D to manufacturing
• Evaluates production processes and oversees development.  Improves and streamlines existing manufacturing processes and procedures.  Evaluates the operation of new and used equipment.
• Procures production tooling for new products and redesigns equipment to work with new products.
• Designs electrical circuits and draws electrical schematics for production equipment.
• Develops and programs PLC programs for production equipment.  Develops and programs programmable servo motors.
• Determines feasibility of decorating requests from customers or Sales department personnel.
• Research, analysis, and validation of new vendors for equipment and supplies.
• Makes recommendations on make and model of equipment to purchase and vendor.
• Oversees CAD Equipment/Product Designer in design, development and implementation of new equipment and products. 
• Plan work and develop a bill of materials for purchased items needed
• Prepares cost estimates for purchased materials and internal labor
• Prepares requests and documents need for the Purchasing Committee and obtains Purchase Committee approval on all discretionary work projects.
• Prepares and maintains specific project task lead-time commitments to meet appropriate priorities.
•  Monitors and tracks projects ensuring that the work is completed according to schedule and with technical excellence.

• Publication of regular project status reports (to be defined for each project) indicating progress against plan, problems or issues encountered, deviations in approach required, impact on schedule and budget (avoid surprises).  Communicates timeline changes to appropriate team members.

• Maintains ongoing list of projects with timeline goals and objectives to be addressed and completed on a regular and timely basis

• Develops understanding of machine controls, settings and operations resulting in development and documentation of processes that yield consistent, predictable, repeatable results (process engineering).
• Evaluates new equipment to ensure that the equipment was built according to plan, operates as designed and meets the specified performance criteria.
• Completion of documentation (operating and maintenance procedures) and training / education for the department TeamMates that will be responsible for the preventive maintenance and the process owners who are responsible for the use, care and safe-keeping of the asset  (where knowledge retention is essential)
• Establishes operating procedures, training programs and implements other needed measures to ensure the proper use, maintenance and care of machinery, and equipment in Print & Assembly and Production Engineering.
• Ensures Shift Managers, Print Supervisors, Quality & Production Supervisors and Quality Production Assistants (as applicable) are familiar with new or modified equipment by developing written set up, operation and maintenance procedures and by explaining and showing how the equipment is to be set up and operated.  The written procedures are to be kept at the machine along with a copy of the equipment manufacturer's operations and maintenance manuals.
• Establishment and implementation of a preventative maintenance program for Print & Assembly as well as workshop equipment provided by and owned Whirley. 
• Develop, implement and coordinate policies on matters involving preventive maintenance
• Determine which categories of equipment or specific pieces of equipment require preventive maintenance, the specific maintenance required and the frequency it should be performed
• Makes timely changes to the preventive maintenance program (keep it current) as equipment is added, modified or taken out of service and to adjust frequency of the preventive maintenance based on the effectiveness of the program
• Establishes an inventory of common wear parts for production tools and equipment.
• Schedule and complete preventive maintenance work due
• Schedule work in a manner that ensures materials and labor resource are available when the job starts so it can be completed as efficiently and cost-effectively as possible 
• Safety enforcement
• Documents preventative maintenance checks and findings in the PMR system.
• Monitors maintenance activities’ ensuring the work is completed with technical excellence, and in an efficient and cost-effective fashion.
• Trouble shoots and diagnoses malfunctioning equipment throughout the Print & Assembly and Production Engineering departments. 
• Works with Industrial Engineer and Shift Managers to build production cells that maximize throughput by identifying and resolving constraints (the bottlenecks).   

 

 
8.   Engineering Database Management – responsible for providing original and revised bill of material and process information to designated TeamMates.  Representive duties include:
 

• Works with the Industrial Engineer to establish manufacturing standards
• Coordination of changes in bills of material or the manufacturing process with Item/Bill of Material Coordinator

• Coordination of changes in pack methods and man seconds for packing with Industrial Engineer

 
9.   Other (not core responsibility) – responsibilities include:
 

• Provides technical support to other departments
• Takes ownership of or actively participates in other projects and key initiatives as assigned or requested
• Maintains ongoing list of projects with timeline goals and objectives to be addressed and completed on a regular and timely basis
• Publication of regular project status reports (to be defined for each project) indicating progress against plan, problems or issues encountered, deviations in approach required, impact on schedule and budget (avoid surprises)
• Complies with federal, state and local requirements by enforcing adherence to requirements and advising management on needed actions
• Continually appraises economic and social forces and government influences and interprets their effect upon the business
• Participates in New product Development and Design and Monday Morning Engineering meetings as requested
• Other duties, as requested