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Director of Operations
Job Purpose: The Director of Operations is responsible for end to end execution of manufacturing operations, with a strong emphasis on manual assembly, Lean manufacturing, and 5S discipline. This leader will be the leader of setting up our KC manufacturing operations; designing assembly stations, production processes and procedures, scalability for future growth, and continuously improve production systems that are efficient, repeatable, and quality driven.
This role requires a hands on operations leader who understands how work actually happens on the floor, how to design assembly lines, balance labor, build quality into the process, and use KPIs to drive predictable outcomes. The ideal candidate will have true hands on experience setting up, running, and improving production assembly processes.
ESSENTIAL JOB FUNCTIONS:
- Setup, lead, and optimize manual assembly operations with a focus on safety, quality, throughput, and labor efficiency
- Design and implement production lines optimized for:
- Takt time and line balance
- Ergonomics and operator efficiency
- Visual flow and minimal WIP
- Establish and maintain standard work for all assembly processes
- Build productions teams, to include assembly, customer repairs, quality assurance, and manufacturing engineering
- Design and build continuously improve layouts, fixtures, tooling, and workflows for production
- Setup and maintain test range facility, safety procedures, and daily operations
Lean Manufacturing & 5S
- Lead deployment and sustainment of Lean manufacturing principles
- Setup parts flow, two bin replenishment
- Setup data collection for assembly and repair, for data collection and live real-time dashboard reporting
- Own and enforce 5S standards across operations:
- Visual management
- Workplace organization
- Sustainment through audits and leader standard work
- Responsible for driving continuous improvement through:
- Process improvement, daily management prioritization, and implementation.
- Waste identification (motion, waiting, defects, overprocessing, etc.)
- Kaizen events and daily improvement
- Root cause problem solving (A3, 5 Why, Fishbone)
- Ensure quality is designed into the process, not inspected in at the end
- Support and oversee quality assurance and ensure:
- Robust control plans
- Error proofing (poka yoke) where applicable
- Clear inspection and acceptance criteria
- Partner with Quality to reduce defects, rework, and escapes
- Lead corrective and preventive actions (CAPA) and drive systemic fixes
- Define, track, and act on operational KPIs, including but not limited to:
- Safety
- Quality (FPY, defect rates)
- Delivery / schedule adherence
- Productivity and labor efficiency
- Scrap and rework
- Build visual dashboards and operating rhythms
- Use data to drive decisions, prioritize improvements, and hold teams accountable
Supply Chain & Production Control
- Manage supply chain to ensure material availability supports production plans
- Ensure effective use and accuracy of:
- Work orders
- Bills of Materials (BOMs)
- Routers / routings
- Improve material flow, kitting, and point of use delivery
- Reduce shortages, expedites, and production disruptions
Manufacturing Engineering Integration
- Building and managing a manufacturing engineering department to support:
- Process development and validation
- Line design and capacity planning
- Cycle time reduction
- New product introductions (NPI)
- Ensure manufacturability, repeatability, and scalability of processes
Leadership & Team Development
- Build, lead, and develop high performing operations teams
- Establish clear expectations, accountability, and ownership
- Coach leaders and supervisors in Lean thinking and problem solving
- Foster a culture of safety, continuous improvement, and respect for
Other
- Support department colleagues as needed
- Complete assigned tasks and required paperwork accurately and on time
- Ensure regular and timely attendance to maintain workflow continuity
- Maintain a clean and organized work area
- Complete other tasks assigned by supervisor or management
- Adhere to all company policies and procedures
What Success Looks Like (12 to18 Months)
- Assembly lines are stable, balanced, and predictable
- 5S is visible, audited, and sustained, not a one time event
- Quality issues are reduced through process control, not inspection
- KPIs are clearly defined, reviewed regularly, and used to drive action
- Teams take ownership of standards and continuous improvement
- The operating model supports scalable growth in a controlled and disciplined manner
To perform this job successfully, you must be able to perform each essential job function satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required.
Education 4 Year Degree
Required Experience & Skills
- 15+ years of progressive operations leadership experience in manufacturing
- Strong background in manual assembly environments
- Demonstrated success implementing and sustaining:
- Lean manufacturing
- 5S
- Standard work and visual management
- Deep working knowledge of:
- Quality systems and QA fundamentals
- Supply chain and production planning
- Manufacturing engineering collaboration
- Work orders, BOMs, and routers
- Proven ability to design and optimize production lines
- Strong analytical skills with experience defining and managing KPIs
- Hands on leadership style with strong shop floor presence
- Maintains proficiency in information technology systems, with the ability to leverage digital tools and platforms to support operational efficiency and data driven decision making
- Experienced in leading and developing high-performing teams
- Strong interpersonal skills; friendly, approachable, motivated, with a strong work ethic and integrity
- Demonstrated ability to effectively manage multiple priorities and meet deadlines
- Detail oriented with strong critical thinking and problem solving skills
- Excellent computer skills including proficiency in Microsoft Outlook, Word, Excel and PowerPoint
- Effective use of electronic communication tools (email, phone systems, etc.)
- Fluent in spoken and written English
- Demonstrate flexibility by supporting critical operations during extended hours, special projects, and peak periods as needed
Preferred Experience & Skills
- Bachelor’s degree in Engineering, Operations, or related field (or equivalent experience)
- Lean certification (Lean, Six Sigma, TPS based training)
- Experience scaling production or stabilizing underperforming operations
- ERP/MRP system experience
- Firearms experience, training, and safety protocols
Supervisory Responsibilities Yes
Travel Requirements Up to 5%
Additional Eligibility Requirements
- Must be at least 18 years old
- Ability to legally possess firearms under applicable laws
- Must know basic firearms safety
- Ability to pass a criminal background test and drug test
PHYSICAL REQUIREMENTS & WORKING CONDITIONS:
The following are the physical requirements of this position, which all workers filling the position must be able to do or withstand each day:
Workload: Medium work: Exerting up to 50 pounds of force occasionally, and up to 20 pounds of force frequently, and up to 10 pounds of force constantly to move objects.
Vision: Maintain close visual acuity for computer work, data analysis, reading, and color recognition.
Mobility: Stooping, kneeling, crouching, reaching, standing for extended periods, walking long distances, pushing, pulling, and lifting as needed.
Dexterity: Perform tasks requiring fingering, grasping, feeling, and repetitive hand or wrist motions.
Communication: Speak clearly, follow and deliver detailed verbal instructions, and hear accurately (with or without correction).
Environment: Work in conditions that may include exposure to fumes, odors, dusts, mists, or gases.
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