Director of Manufacturing Operations

Description

Director of Manufacturing Operations

Westlake Plastics is a world-leading manufacturer in extrusion and compression molding technologies of high-performance thermoplastics. Close collaboration with our customers and new product development have been the hallmarks as we celebrate 75 years of success.

We are seeking a candidate that can lead production, supply chain, facilities and warehousing providing operational guidance that instills continuous improvement and a culture of accountability to deliver high-quality, cost-effective thermoplastic extruded stock shapes products and achieve the company’s operational goals. The ideal candidate would be strategic and a hands-on manufacturing operations leader with a deep understanding of lean principles, who leads by influence, facilitates cross functional collaboration, and communicates effectively to drive safe and cost effective-business results.

The Director of Manufacturing Operations is responsible for leading and optimizing manufacturing operations for the thermoplastic extrusion sites in the Greater Philadelphia area of Pennsylvania. Reporting to the General Manager, this role oversees all aspects of operations including manufacturing, supply chain, facilities and warehousing with accountability for quality, safety, delivery, and cost effectiveness. This position works closely with the Director of Engineering Management to ensure operational excellence [RC3.1], alignment with company strategy and a culture of accountability [RC4.1]. 

The Director will provide strategic and hands-on leadership across two production sites and warehousing facility, driving continuous improvement while leveraging deep technical expertise in thermoplastic extrusion. This role requires a proven ability to foster strong cross-functional collaboration [RC5.1] and to lead a team in the manufacturing of high-quality products that meet customer requirements. 

Requirements

 Leadership & Organizational Development

• Lead, mentor, and develop a high-performing, multi-site operations team. [RC6.1]

• Recommend and implement plan to develop professional and managerial skills of direct reports

• Set clear performance expectations and provide regular oral and written feedback

• Establish a culture of accountability, professional development, and operational discipline.

• Gain clear understanding of overall business objectives and goals and encompass them into operational goals

Manufacturing & Operations Management

• Oversee daily manufacturing operations to ensure safe, efficient, and high-quality production.

• Create and manage KPIs related to operational productivity, 

• Lead collaborative efforts between supply chain and extrusion management to ensure production schedules, and customer commitments are consistently met [RC7.1]

• Assess and balance workload by department to ensure each operational stage is efficient and free of bottlenecks. [RC8.1]

Process Optimization & Continuous Improvement

• Drive Lean manufacturing, Six Sigma, and waste-reduction initiatives across all sites.

• Utilize business analytical systems to enhance visibility, control, and performance of production operations.

• Perform root cause analysis and implement corrective and preventive actions.

Technical Leadership

• Leverage expertise in thermoplastic Rod, Film, sheet and slab extrusion to optimize processes, troubleshoot issues, and improve product quality and yield.

• Partner with Engineering, Quality, and R&D on product and process development, validation, transfer of product development to manufacturing stage.

Regulatory Compliance & Quality Systems

• Ensure compliance with ISO 9001-13485, standards [RC9.1] and all relevant environmental, health, safety, and regulatory requirements at the local, state, and federal levels.

• Maintain audit readiness and oversee documentation, inspections, and regulatory interactions.

• Develop and modify processes and procedures as needed in manufacturing, supply chain, and shipping operations.

Facilities & Equipment Management

• Oversee facility operations to ensure a safe, OSHA compliant manufacturing environment.

• Direct equipment maintenance, calibration, and preventive maintenance programs to minimize downtime and maximize reliability.

• Prepare and present requests for capital improvements related to process, product capacity and capability upgrade initiatives as needed. [RC10.1]

Cross-Functional Collaboration

• Partner effectively with Leadership, Quality, Engineering, R&D, Sales and Customer Service and other stakeholders to align operations with business objectives. [RC11.1]

• Communicate clearly and effectively with internal teams and senior leadership.

• Work closely with HR on all matters concerning operations employee retention, hiring, terminations, safety and development.

• Collaborate with the CEO and executive team to develop and execute strategic initiatives focused on efficiency, growth, sustainability, and profitability; Implement and manage operational plans

• Manage coordination and information flow between the finance, production, purchasing, quality, sales, and regulatory affairs departments for production and shipping activities

• Work with the Director of Engineering Management to define requirements for equipment, tooling, and infrastructure needed to increase productivity; develop and present the business case to the leadership team for approval

• Set and review budgets and manage operating expenses for the company’s operations, work with the CFO in preparation of the annual budget and the operating and capital expense plan

• Assist the Quality and Sales Team in resolving inquiries concerning production quality. [RC12.1]

Key Competencies

· Strategic and operational leadership [RC13.1]

· Regulatory and quality-driven mindset

· Data-driven and analytical problem solving

· Continuous improvement and Lean manufacturing

· Cross-functional collaboration and communication [RC14.1]

Education & Experience

• Bachelor’s degree in operations management or process engineering, or a related field required; Plastics engineering and advanced degree (MBA, MSEM) preferred. [RC15.1]

• 10–15+ years of operations leadership experience, with significant experience in thermoplastics extrusion.

• Demonstrated success leading operations in [RC16.1] strategic orientation and ability to coordinate complex cross functional projects. 

• Proven multi-site leadership experience.

Technical & Professional Skills

• Deep expertise in thermoplastic extrusion processing.

• Strong knowledge of GMP manufacturing and regulatory frameworks.

• Experience with MES, SCADA, SPC, and process improvement methodologies (Lean, Six Sigma).

• Solid understanding of facility and equipment maintenance in regulated manufacturing environments.

• Exceptional communication, leadership, and interpersonal skills.

• Demonstrated ability to use ERP systems, Microsoft office suite, power BI experience

Additional Requirements

• Ability to operate effectively in a fast-paced, dynamic environment with competing priorities.

• Proficiency in English required; additional languages are a plus.