Plant Manager

Headquartered in Buffalo Grove, Illinois. PPC FLEX™ (PPC) has steadily grown and evolved, organically and through acquisition, into a premier, high-quality flexible packaging manufacturer. As a dynamic team of design and packaging professionals, PPC provides creative packaging solutions. The company’s capabilities and speed to market have always been PPC’s greatest strength, establishing the organization as a trusted leader within the consumer and cleanroom markets. 

The Healthcare and Specialty business group is a dynamic team of design and packaging professionals dedicated to providing creative packaging solutions. Our capabilities and speed to market have always been our greatest strengths. PPC FLEX’s Precision Clean® Cleanroom products are produced in our state-of-the-art ISO Class 4 and ISO Class 7 Cleanrooms. A comprehensive ISO-certified quality system supports the cleanroom packaging business, and a fully equipped quality test laboratory.

Plans, directs, and coordinates the daily on-site cleanroom manufacturing operations for the Healthcare and Specialty Business Unit, with a focus on the Buffalo Grove Headquarters location.  Manages utilization of equipment, facilities, and personnel to obtain maximum efficiency and meet performance objectives in a cleanroom manufacturing environment. Drives continuous improvement in plant productivity through lean processes.  Develops the operations team to achieve performance and a safe work environment.  Manages the operations side of the P&L to achieve EBITDA targets, ensuring OTIF rates above 95%, and leads the team in adopting a continuous improvement mindset.  Oversee production (hands-on approach, understanding all aspects of equipment setup and efficiencies), planning and scheduling, procurement, maintenance, warehouse, and quality teams. Leads by example and drives alignment with the facility's goals and objectives, while interacting with other facility managers to establish best practices and integrate cross-functional leverage for CAPEX, maintenance, and procurement.

Responsibilities:

•    Cultivates a “safety first” culture across all locations and departments.  

•    Aligns with senior management on the vision, business goals, and objectives.  

•    possesses strong communication and presentation skills, capable of delivering clear and concise presentations; a strong influencer who builds rapport and credibility with operations personnel.  

•    Results-oriented, assertive, and tenacious, yet diplomatic when it comes to completing tasks on time. This position requires multitasking and an individual who thrives on a sense of urgency, demonstrates creative problem-solving abilities, and effectively resolves challenges in manufacturing and supply chain processes. Follows through on commitments.  

•    Collaborate daily with plant supervision and floor personnel to enhance productivity and ensure optimized manufacturing processes are implemented.  

•    Conducts daily Gemba meetings with area supervisors to review key performance indicators (KPIs) related to production.  

•    Monitors daily floor performance and ensures that visual manufacturing methods are utilized to communicate performance and goals.  

•    Ensures that product quality objectives are met and collaborates with the Quality team to address customer quality issues and implement corrective action plans.  

•    Works closely with the operations team to guarantee adherence to manufacturing processes.  

•    Partners with the Maintenance Manager to establish preventive maintenance and machine reliability programs, ensuring compliance with maintenance schedules.  

•    Participates in production planning meetings to set manufacturing priorities and resolve obstacles to meet productivity and inventory objectives.  

•    Reviews weekly KPI performance and implements corrective action plans when goals are not achieved.  

•    Integrates with commercial leadership to understand demand forecasts and plan for material and cost savings aligned with annual volumes.  

•    Collaborates with the commercial team to ensure timely completion of successful product trials and qualifications.  

•    Works with Customer Service to address the on-time delivery needs of customers.  

•    Monitors all internal systems for accuracy and compliance with company rules, standards, expectations, and applicable laws.  

•    Manages manufacturing projects using MS Project, setting priorities, and communicating progress while adhering to schedules.  

•    Reviews manufacturing variances to identify root causes of inefficiencies and costs, implementing necessary corrective actions.  

•    Prepares budgets for approval, including funding for projects and program implementations.  

•    Develops ROI calculations for new capital expenditure projects and utilizes Microsoft Project Plans to ensure timely completion and adherence to budget expectations.  

•    Resolves problems by adjusting priorities, schedules, and reallocating the workforce as necessary.  

•    Controls and consistently reduces obsolete and excessive inventory and provides inventory models to maintain effectiveness and accuracy.  

•    Confirms that the plant meets contractual obligations to customers.  

•    Ensures sufficient capacity is available to fulfill objectives and deliver products.  

•    Reviews of all internal and external reporting.  

•    Works with the operations team to develop training programs.  

•    Ensures proper cross-training of machine operators and documents which personnel are trained on specific equipment.  

•    Analyzes operations to assess performance against objectives and identify areas for potential cost reduction or program improvement.  

•    Approves and monitors work completion and performance by contractors.  

•    Fully understands company policies and ensures disciplinary actions are enforced as required, collaborating with Human Resources to maintain adherence to these policies.  

•    Actively participates in and promotes the Continuous Quality Improvement process.  

•    Motivates, outlines, and delegates methods to exceed company goals.  

•    Drives continuous improvement through corrective actions, cost-saving initiatives, and utilizes tools designed to eliminate waste and reduce process variability.  

•    Maintains strong relationships in the Healthcare, Pharmaceutical, and Medical Device packaging industries.

Education & Experience:

•    A four-year bachelor’s degree, engineering or science degree preferred, and 7+ years’ experience in a similar role in Healthcare, Cleanroom, or Food and consumer Packaging

•    Minimum of 8-10 years of progressive leadership experience in a flexible packaging manufacturing environment.  Flexographic printing, cleanroom converting (pouching, flat bags, Tyvek sheets, peel pouches, Rollstock, slitting, and tubing).

•    Has experience leading a $75 million facility with approximately 75 unionized employees.  

•    Has experience managing multiple facilities and warehouses

•    Experience in proper clean room manufacturing process, ISO class 4 and ISO 7

•    Familiar with ISO 13485 and ISO 9001

•    Knowledge of medical, pharmaceutical, dental, and scientific packaging markets.

•    Experience in flexible packaging and/or flexographic printing preferred. Knowledge of Digital Printing is desired.

•    5+ years’ experience using an ERP system. (Radius)

•    Previous experience implementing Kaizen, SQF, Lean Manufacturing, and GMP processes.

•    Black belt in Lean.

•    A bachelor’s degree in engineering or a technical-related field is required.

•    Thorough knowledge of MS Outlook, Excel, Word, and PowerPoint required.

•    Experience maintaining confidential information and the ability to handle issues with discretion and good judgment.

•    Must have strong attention to detail, the ability to work independently, and excellent collaboration skills to partner effectively across all business units and states.

•    Planning and project management skills, including the ability to prioritize multiple projects and deadlines. Strong problem-solving skills are essential.

•    Bi-lingual, English/Spanish-speaking language capability is a plus.

•    Demonstrated strong relationship-building skills with production employees and staff.

•    Previous experience managing in a unionized manufacturing environment preferred.

•    Desire to win and be successful

PPC Flex is a premier flexible packaging manufacturer. Our capabilities have established us as a trusted leader within consumer and cleanroom markets.