Operational Excellence (OpEx) Manager

Position Summary

As head of the Engineering Department, The Operational Excellence (OpEx) Manager is responsible for leading the facility's continuous improvement strategy, driving operational efficiency, and implementing standardized systems that support sustainable business performance. This role serves as the site champion for the Carlex Operating System, ensuring consistent execution, accountability, and alignment with corporate operational standards.

A key success factor for this position is maintaining focus on systemic, long-term operational improvements and preventing the Continuous Improvement (CI) and Operational Excellence functions from becoming consumed by daily production firefighting. The OpEx Manager will drive KPI ownership across all departments, lead strategic waste and scrap reduction initiatives, establish robust problem-solving processes, and foster a culture of accountability and continuous improvement throughout the organization.

Key Responsibilities

Strategic Leadership & System Integration

• Lead the implementation, adoption, and continuous improvement of the Carlex Operating System across the facility.
• Evaluate and challenge existing operating system standards to improve specificity, accountability, and consistency across all Carlex locations.
• Establish standardized operational methods and best practices that support corporate objectives and site performance goals.
• Provide strategic leadership for continuous improvement activities while protecting CI and OpEx resources from daily operational firefighting.
• Ensure improvement efforts remain focused on sustainable, systemic solutions that drive long-term business results.

KPI Management & Accountability

• Develop, analyze, and communicate plant-wide KPI reporting to provide visibility into operational performance.
• Drive data-based decision making and continuous performance improvement throughout the facility.
• Hold department leaders accountable for achieving KPI targets and ensuring corrective action plans are developed and executed when performance falls below expectations.
• Facilitate performance reviews and follow-up processes that ensure ownership of key business metrics across all functional areas.

Scrap Reduction & Cost Improvement

• Lead the strategic deployment and execution of the "STOP Scrap" initiative across the facility.
• Identify and prioritize high-impact scrap reduction opportunities through data analysis and structured problem-solving techniques.
• Collaborate with Operations, Engineering, Quality, and Production leadership to implement corrective actions that reduce waste and improve profitability.
• Monitor progress, track results, and communicate savings generated through scrap reduction initiatives.

Root Cause Analysis (RCA) & Problem-Solving Leadership

• Drive a culture of structured problem solving and ensure clear ownership of corrective actions throughout the organization.
• Deploy and train teams on Root Cause Analysis methodologies including 8D, 5-Why, Ishikawa (Fishbone), and other continuous improvement tools.

Line-Level Problem Solving

• Implement and roll out standardized RCA tools and processes across Operations.
• Coach operational teams on effective problem-solving techniques while maintaining Operations ownership and execution responsibility.
• Hold Operations leadership accountable for investigating and resolving operational breakdowns, inefficiencies, and recurring issues.

Customer & Quality Problem Resolution

• Partner with the Quality Management team to support formal customer complaint investigations and 8D response activities.
• Ensure robust corrective and preventive actions are developed, implemented, and verified for effectiveness.
• Assist in driving cross-functional efforts to eliminate recurring quality concerns and improve customer satisfaction.

Team Leadership & Development

• Lead and develop the Engineering Lead and Continuous Improvement Coordinator to support operational excellence objectives.
• Foster a culture of accountability, engagement, collaboration, and continuous learning.
• Mentor leaders and employees on Lean principles, process improvement methodologies, and problem-solving techniques.
• Promote employee involvement in continuous improvement initiatives throughout the organization.

Qualifications & Requirements

• Bachelor's degree in Engineering, Operations Management, Manufacturing, Business, or a related field preferred.
• Minimum of 5-7 years of leadership experience in manufacturing, process engineering, operational excellence, or continuous improvement environments.
• Proven experience implementing, sustaining, and improving corporate operating systems and standardized work processes.
• Strong leadership presence with demonstrated ability to influence cross-functional teams and hold peer leaders accountable for performance results.
• Extensive knowledge of Lean Manufacturing, Continuous Improvement, and Operational Excellence principles.
• Deep understanding of Root Cause Analysis methodologies, including 8D, 5-Why, Ishikawa (Fishbone), and structured problem-solving techniques.
• Experience leading KPI-driven performance management systems and large-scale operational improvement initiatives.
• Strong analytical, communication, facilitation, and project management skills.
• Demonstrated success in reducing waste, scrap, and operational inefficiencies through structured improvement efforts.

Key Success Measures

• Successful implementation and sustainment of the Carlex Operating System.
• Achievement of plant KPI targets and increased departmental ownership of performance metrics.
• Measurable reductions in scrap and waste through STOP Scrap initiatives.
• Increased effectiveness of RCA processes and reduction of recurring operational issues.
• Sustained focus of CI and OpEx resources on strategic improvement activities rather than daily firefighting.
• Development of a culture of accountability, standardization, and continuous improvement across the facility.