DIRECTOR OF MANUFACTURING AND QUALITY

The Caldwell Group Inc•Rockford, IL

About The Position

The Director of Manufacturing & Quality provides strategic and operational leadership across manufacturing, quality, maintenance, and warehouse operations to ensure safe, efficient, and high‑quality output. The role oversees plant‑wide systems, performance management, cross‑functional alignment, and continuous improvement. Day‑to‑day shop‑floor execution is led by the Plant Manager and functional leads, while the Director sets standards, establishes KPIs, removes barriers, and drives sustainable results in safety, quality, delivery, cost, and people development.

Requirements

Bachelor’s degree in Manufacturing, Engineering, Operations, or related field required
7–10+ years of manufacturing leadership in a complex or multi‑process production environment.
Demonstrated success leading through managers/leads
Strong understanding of quality systems, production planning, and operational excellence.
Experience with ERP‑enabled operations (M1 preferred).
Manufacturing acumen and structured problem‑solving.
Data‑driven decision‑making; strong analytical capability.
Quality management and root‑cause analysis expertise (A3/8D/SPC).
Leadership, communication, and team development across shifts and functions.
Lean/continuous improvement mindset; ability to standardize and sustain.
ERP fluency (preferably M1); strong discipline in master data and transactions.

Nice To Haves

Master’s (MBA/Engineering/Operations) a plus.
Lean Six Sigma (Green/Black Belt)
PMP or equivalent change/implementation credentials
OSHA training.

Responsibilities

Provide strategic direction to Plant, Quality, Maintenance, and Warehouse leaders to meet safety, quality, delivery, and cost targets.
Lead weekly operating reviews; analyze KPIs (e.g., OEE, FPY, COPQ, on‑time delivery, inventory accuracy) and drive corrective actions.
Support the Plant Manager in resolving escalations and removing barriers to throughput, staffing, and materials availability.
Ensure cross‑functional alignment with Engineering and Supply Chain on specifications, BOMs, routings, drawings, and work instructions.
Own the Quality Management System (QMS); ensure effective NCR/CAR processes, internal audits, supplier quality management, and gauge/calibration programs.
Improve first‑pass yield and reduce scrap, rework, and cost of poor quality (COPQ) through structured root‑cause analysis and CAPA.
Establish and maintain quality dashboards; lead routine quality performance reviews and management of change.
Ensure accurate, complete manufacturing information from upstream functions to prevent defects at the source.
Deploy Lean methodologies (5S, visual management, standard work, Kaizen) to drive waste reduction and flow.
Improve OEE through constraint management, SMED/quick changeover, and disciplined maintenance practices.
Standardize work instructions, process controls, and revision discipline across production areas.
Champion a data‑driven culture; use Pareto, SPC, and problem‑solving (A3/8D) to prioritize and sustain improvements.
Oversee the work‑order lifecycle (creation, release, change control, labor reporting, and closeout) to ensure timely, accurate reporting.
Maintain accurate BOMs, routings, work centers, and standards within the ERP (M1 preferred).
Drive data integrity and real‑time visibility to support daily management and month‑end close.
Own inventory accuracy, cycle counting discipline, and material movement standards within the ERP.
Establish stocking strategies, reorder points, and FIFO controls aligned to production needs and lead‑time risk.
Reduce slow‑moving/obsolete inventory; improve turns and working capital health.
Oversee maintenance strategy, PM compliance, critical spares, and reliability engineering to achieve uptime targets.
Align equipment capabilities and capacity with the production plan; support capital planning and plant layout improvements.
Ensure a strong safety culture, regulatory compliance (e.g., OSHA), and effective incident prevention and response.
Build, mentor, and coach a high‑performing leadership team including the Plant Manager, Quality Lead, Maintenance Lead, and Warehouse Lead.
Develop leadership capability through structured coaching, regular feedback, succession planning, and skill‑development pathways.
Establish a culture of accountability, empowerment, and continuous learning across all levels of the organization.
Ensure managers are effectively leading their teams, maintaining strong communication, and fostering employee engagement.
Promote a culture that values safety, integrity, collaboration, and problem‑solving.
Champion workforce development programs including onboarding, cross‑training, and technical skills development.