Location: Boulder, Colorado
Reports To: Chief Operations Officer (COO)
Job Type: Full-Time, Permanent
Compensation: Competitive Salary + Bonus + Benefits Package
Job Summary:
The Director of Manufacturing and Quality is a senior leadership position responsible for overseeing all aspects of manufacturing operations and quality assurance within the organization. This role ensures that the manufacturing processes are efficient, cost-effective, and capable of delivering high-quality products that meet customer expectations, industry standards, and regulatory requirements. The Director will drive strategic initiatives, continuous improvements, and innovation while managing a diverse team of engineers, quality managers, and production staff.
Key Responsibilities:
Manufacturing Leadership:
- Strategic Production Oversight: Lead and manage the manufacturing processes, ensuring that production goals are met on time, within budget, and with the highest standards of quality.
- Capacity Planning: Assess current and future production needs and manage resource allocation (labor, materials, machinery) to meet customer demand.
- Process Optimization: Continuously evaluate and improve manufacturing processes using Lean, Six Sigma, and other industry best practices. Reduce cycle times, enhance product quality, and minimize waste.
- Technology Integration: Identify and implement new manufacturing technologies or software to improve production efficiency and reduce costs.
- Production Scheduling: Develop and manage production schedules, monitor real-time performance, and make adjustments to meet delivery deadlines while balancing resources and inventory.
Quality Management:
- Quality Control and Assurance: Develop, implement, and maintain a robust Quality Management System (QMS) to ensure product quality throughout the entire production process. Oversee the testing and inspection of raw materials, in-process components, and finished products.
- Regulatory Compliance: Ensure compliance with regulatory requirements, including ISO 9001, AS9100, FDA, and any other applicable standards. Manage internal audits, external audits, and certifications.
- Root Cause Analysis and Corrective Actions: Lead investigations into quality issues, perform root cause analysis, and drive corrective and preventive actions to eliminate defects and improve manufacturing processes.
- Continuous Improvement: Promote a culture of continuous improvement and ensure that all quality issues are addressed through ongoing training, coaching, and system enhancements. Lead Six Sigma and Lean initiatives to improve quality, reduce variability, and improve operational performance.
Team Leadership and Development:
- Leadership & Team Building: Lead a cross-functional team of engineers, production managers, quality assurance professionals, and support staff. Provide guidance, mentorship, and performance feedback to ensure a high level of engagement and performance.
- Talent Development: Build and nurture a high-performing team by identifying and developing talent, fostering an environment of professional growth and skill development.
- Collaboration: Work closely with R&D, engineering, supply chain, and logistics teams to align production efforts with product development, procurement, and customer demand.
- Cross-Functional Communication: Serve as the liaison between production, quality, and senior management, ensuring the flow of information and alignment across all departments.
Safety and Regulatory Compliance:
- Workplace Safety: Lead safety programs and ensure that all manufacturing activities comply with OSHA and other safety regulations. Foster a safety-first culture across all manufacturing operations.
- Environmental and Sustainability Compliance: Ensure that the manufacturing operations comply with environmental regulations, focusing on sustainability, waste reduction, and responsible material use.
- Audit Preparation: Prepare for internal and external audits and ensure that the manufacturing and quality operations are always ready for inspection.
Cost Control and Budgeting:
- Cost Management: Oversee and manage the budget for manufacturing and quality departments, ensuring the efficient use of resources while minimizing waste and operational costs.
- Cost Reduction Initiatives: Identify opportunities for cost savings across the production process, through process improvements, material cost reductions, or energy efficiency improvements.
- Capital Planning: Lead the budgeting and forecasting process for capital investments in new equipment, technology, and facilities. Prioritize and manage capital expenditures to optimize production capacity and product quality.
Skills & Qualifications:
Education:
- Bachelor’s Degree in Engineering (Mechanical, Industrial, Manufacturing, or related field) or Business Administration.
- Master’s Degree in Business Administration (MBA), Engineering, or Manufacturing Management is a plus.
- Certifications: Lean Six Sigma (Green Belt, Black Belt) and/or ISO 9001 Lead Auditor Certification are highly desirable.
Experience:
- Minimum 10 years of experience in manufacturing and quality management, with at least 5 years in a leadership role managing teams and overseeing production and quality assurance functions.
- Proven experience in advanced manufacturing environments (e.g., aerospace, medical devices, automotive, electronics) where product quality is critical.
- Extensive experience in implementing Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
- Proven track record of leading quality improvement initiatives that resulted in tangible improvements in production efficiency, cost reduction, and product quality.
- Experience with ISO 9001, AS9100, or similar industry certifications and regulatory compliance standards.
Skills:
- Leadership & Team Development: Ability to lead, motivate, and mentor cross-functional teams to achieve high levels of performance and continuous improvement.
- Strategic Thinking: Strong business acumen and ability to drive strategic initiatives to optimize manufacturing processes, improve product quality, and align operations with organizational goals.
- Analytical & Problem-Solving Skills: Advanced proficiency in analyzing data, identifying inefficiencies, and implementing corrective actions. Knowledge of Root Cause Analysis (RCA) and Failure Mode Effects Analysis (FMEA).
- Communication Skills: Exceptional communication skills, both written and verbal, with the ability to communicate complex technical information to both technical and non-technical stakeholders.
- Project Management: Strong organizational and project management skills, with the ability to prioritize tasks, manage multiple projects simultaneously, and meet deadlines.
- ERP & Manufacturing Software Proficiency: Proficiency with ERP systems (e.g., SAP, Oracle) and Manufacturing Execution Systems (MES). Familiarity with CAD, PLM software is a plus.
Technical Skills:
- Manufacturing Process Knowledge: Extensive experience with manufacturing techniques such as SMT and CNC machining, molding, assembly, and additive manufacturing.
- Quality Management: Strong understanding of Quality Management Systems (QMS), Statistical Process Control (SPC), Design of Experiments (DOE), and Process Capability Studies.
- Statistical Analysis Tools: Experience using statistical software for quality data analysis (e.g., Minitab, JMP, Excel).
- Regulatory Compliance: In-depth knowledge of FDA regulations, ISO standards, and Good Manufacturing Practices (GMP) for regulated industries.
Personal Attributes:
- Detail-Oriented: Strong attention to detail with the ability to identify and address quality issues before they impact production or customer satisfaction.
- Adaptability: Ability to manage change effectively and respond positively to new challenges or market shifts.
- Results-Oriented: A focus on achieving goals, improving key performance indicators (KPIs), and delivering tangible results that drive business success.
- Collaborative & Approachable: Strong interpersonal skills with the ability to foster a collaborative work environment, building relationships across various teams and functions.
Working Conditions:
- This position is based in a manufacturing facility on the production floor.
- Work involves standing, walking, and some lifting of equipment (up to 25 pounds).
Compensation and Benefits:
- Competitive salary commensurate with experience.
- Bonus and profit-sharing potential.
- Comprehensive benefits package, including:
- Health, dental, and vision insurance.
- 401(k) retirement plan with company match.
- Paid time off (PTO), holidays, and sick leave.
- Professional development opportunities.
- Relocation assistance (if applicable).
This is a high-level and strategic leadership role that demands a strong blend of technical expertise, process improvement knowledge, and leadership experience. The Director of Manufacturing and Quality will play a key role in shaping the company’s manufacturing operations and quality practices, contributing directly to the company’s long-term growth and success.