Executive Director, Project Management, Industrialization

Blue Bird Corporation•Detroit, MI

5d•Onsite

About The Position

The Executive Director, Project Management, Industrialization will lead manufacturing and production readiness for Blue Bird’s next-generation F53/F59 chassis platform. The role integrates Plan for Every Part (PFEP), continuous improvement, Lean manufacturing, and operational excellence into an industrialization plan supporting Q1 2028 production within approved budget, schedule, safety, and quality requirements. This is a hands-on position accountable for developing and maintaining detailed project plans, resolving plant-level execution issues, and influencing cross-functional action without direct reports. Responsibilities extend beyond launch to sustaining PFEP, improving operating performance, and developing repeatable manufacturing and supply chain practices. The position coordinates facilities, tooling, equipment, materials flow, process capability, quality systems, workforce readiness, and production ramp. It also develops and maintains PFEP, translates materials data into practical plant processes, supports logistics planning, and leads continuous improvement initiatives. The role works in both office and production environments, including manufacturing areas with exposure to heat, cold, noise, moving objects, and sheet metal. Appropriate PPE must be worn when and where required. Frequent weeks exceed 40 hours, and the role involves frequent communication throughout the day.

Requirements

Bachelor’s degree in engineering, operations, manufacturing, supply chain, or a related field.
10+ years of project management, manufacturing launch, industrialization, operations, plant engineering, or production readiness experience.
8+ years of demonstrated experience implementing PFEP or comparable part-level materials planning systems and leading Lean, continuous-improvement, or operational-excellence initiatives in a manufacturing environment.
Strong knowledge of manufacturing launch, capital projects, equipment installation, process validation, quality readiness, workforce planning, and production ramp execution.
Practical expertise in PFEP, material flow design, inventory management, replenishment systems, and integration of materials processes with production requirements.
Ability to apply Lean and continuous-improvement methods to operational problems and sustain measurable results.
Ability to lead through influence, secure cross-functional commitments, resolve competing priorities, and escalate issues with clear recommendations.
Strong planning, documentation, analytical, and project management skills, including the ability to build and maintain detailed schedules, trackers, and performance reports.
Ability to work between leadership discussions and detailed production-floor work, adapt to changing requirements, and maintain accountability for results.
Must be a U.S. citizen or permanent resident and authorized to work in the United States; proof of employment eligibility is required at hire.
Must wear appropriate PPE when and where required.

Nice To Haves

Exposure to difficult or complex projects.
Ability to anticipate and understand customer needs and provide guidance.
Excellent interpersonal and customer relationship skills, including handling difficult and sensitive matters.
Ability to influence stakeholders and communicate complex details clearly.
Ability to work in a collaborative team and balance stakeholder needs while delivering corporate objectives.
Flexibility to work in flexible workspaces and work hours.

Responsibilities

Develop, document, and maintain the integrated industrialization plan, including milestones, dependencies, accountable owners, resources, readiness criteria, and recovery actions.
Drive production realization across facilities, tooling, equipment installation, line layout, manufacturing processes, quality readiness, staffing, training, materials management, and chassis shipping.
Track capital milestones, budget commitments, capacity assumptions, process validation, and production ramp readiness; work with functional owners to close gaps and escalate launch decisions.
Work directly with plant teams to validate production-floor readiness, resolve execution issues, and manage risks to safety, quality, cost, delivery, and business continuity.
Lead development, implementation, and ongoing maintenance of PFEP with supply chain, materials, manufacturing engineering, and production teams, including data ownership and change controls.
Ensure PFEP defines part requirements, supplier and lead-time information, packaging, storage locations, inventory parameters, replenishment methods, and point-of-use delivery requirements.
Translate PFEP into receiving, storage, kitting, line-side delivery, and replenishment processes; validate material availability and flow against production demand, space, handling, safety, and capacity requirements.
Use PFEP data to identify and reduce shortages, excess inventory, unnecessary handling, and production interruptions, coordinating corrective actions with functional owners.
Support inbound and outbound logistics plans with plant team members and third-party vendors, including delivery schedules, transportation capacity, staging, and finished chassis shipping aligned with production demand and ramp requirements.
Develop and execute a prioritized continuous-improvement and operational-excellence roadmap for launch readiness and sustained post-launch performance, with baselines, owners, milestones, and measurable benefits.
Lead Lean initiatives such as value stream mapping, standard work, 5S, visual management, line balancing, and structured problem-solving to improve safety, quality, productivity, material flow, and delivery.
Facilitate improvement events and coach plant teams in root-cause analysis and corrective action; establish follow-up routines and measures to verify improvements are adopted and sustained.
Document repeatable manufacturing and supply chain practices, lessons learned, and standard processes; support their application across other Blue Bird operations as assigned.
Develop and maintain detailed schedules, trackers, and performance reports, and influence cross-functional stakeholders to resolve competing priorities and escalate issues with recommendations.