Operations Manager; Foam

Ashley Furniture Industries•Tupelo, MS

1d•$100,000 - $120,000•Onsite

About The Position

The Manager of Foam Fabrication directs production activities for multiple departments, work centers, and processes on an assigned shift, leading the foam production operations that are critical to Ashley's furniture manufacturing excellence. This leadership role leads and mentors production supervisors to achieve overall performance goals for production output, cost efficiency, quality standards, and safety compliance. The Operations Manager coordinates production activities through strategic planning with departmental supervisors, schedulers, HR managers, and quality systems trainers to ensure that manufacturing objectives are accomplished in a timely and cost-effective manner while optimizing foam production processes and product quality.

Requirements

Associate's degree in Business, Chemical Engineering, Manufacturing Technology, or related field required (or equivalent work experience)
Minimum 5 years of experience in foam pouring production leadership or related manufacturing area
Proven supervisory or management experience with direct reports
Management of resources to optimize equipment, facilities, employees, methods, and materials
Strong understanding of Lean Manufacturing and continuous quality improvement principles
Experience with system improvement methods, capacity planning, and product flow optimization
Knowledge of polyurethane foam chemistry and production processes
Excellent leadership and team-building skills with ability to motivate and develop high-performing teams
Strong analytical and problem-solving abilities with data-driven decision-making approach
Excellent communication and interpersonal skills with ability to collaborate across all organizational levels
Proficient in Microsoft Office Suite (Excel, Word, Outlook)
Ability to work flexible hours including evenings, weekends, and holidays as operational needs require
Physical ability to walk production floors, stand for extended periods, and work in manufacturing environment with chemical exposure

Nice To Haves

Bachelor's degree in Chemical Engineering, Industrial Engineering, Operations Management, or related field
7+ years of foam manufacturing or chemical processing experience in furniture, bedding, or related industry
Lean Six Sigma certification (Green Belt or Black Belt)
Experience with ERP systems (SAP, Oracle, or similar platforms)
Background in budgeting, financial analysis, and P&L management
Knowledge of OSHA regulations, environmental compliance, and chemical safety management
Experience with automated foam pouring systems and advanced manufacturing technologies
Project management experience with capital improvement initiatives
Understanding of quality management systems and statistical process control
Advanced degree (MBA) or professional certification in operations or manufacturing management

Responsibilities

Direct production activities for multiple departments, work centers, and processes on an assigned shift to meet production targets and quality standards
Lead the efforts to develop new processes and improve product quality by working with internal and external customers and suppliers
Plan in a forward capacity by working with purchasing, production planning, and inventory control to achieve and maintain product flow to meet production and financial objectives
Ensure that shift personnel adhere to the highest standards of shop floor organization, plant cleanliness, and 5S principles
Monitor production schedules and adjust priorities to meet changing business needs and customer requirements
Coordinate with other shift managers to ensure seamless 24/7 operations and effective handoffs
Work to maintain budget for functional area including labor, materials, utilities, and overhead costs
Monitor and control departmental costs while maintaining production and quality standards
Identify cost reduction opportunities without compromising safety or quality
Track and report on financial performance metrics and variances
Optimize resource utilization to maximize efficiency and minimize waste
Ensure adequate staffing to meet production needs through effective workforce planning and scheduling
Make employment decisions and/or recommendations on hiring, improvement plans, transfers, promotions, corrective actions, terminations, pay adjustments, etc.
Coordinate and manage the work of employees by directing members of the team to meet the area's goals and production objectives
Audit regularly to ensure standard operating procedures are being adhered to and quality standards are maintained
Manage employee performance and assist employees in making improvements to their performance through coaching, mentoring, and administering performance reviews
Recommend, plan, and/or implement employee training and skill development activities to build organizational capability
Audit, maintain, and ensure employee time-keeping and absentee records are accurate and comply with company policies
Communicate company and departmental issues and goals through weekly team meetings, regular individual employee meetings, coaching, training, and company-offered learning opportunities
Facilitate employee growth and development by identifying career paths and providing developmental opportunities
Ensure employees receive proper safety training, maintain a safe work environment, and perform safe work practices at all times
Perform regular safety audits and address unsafe conditions or behaviors immediately
Ensure compliance with OSHA regulations, environmental regulations, and chemical handling requirements
Lead safety meetings and promote a culture of safety awareness throughout the foam fabrication operations
Investigate incidents, implement corrective actions, and prevent recurrence
Ensure proper use of personal protective equipment (PPE) including respirators and protective clothing
Lead continuous improvement initiatives using Lean Manufacturing and continuous quality improvement principles
Implement system improvement methods to enhance efficiency, reduce waste, and improve product quality
Conduct capacity planning and optimize product flow to maximize throughput and minimize bottlenecks
Monitor foam quality parameters including density, firmness, consistency, and dimensional accuracy
Collaborate with Quality Assurance teams to resolve quality issues and implement corrective actions
Participate in root cause analysis and problem-solving activities
Coordinate production activities through planning with departmental supervisors, schedulers, HR managers, and quality systems trainers
Work closely with engineering, maintenance, quality, and supply chain teams to support operational excellence
Partner with suppliers on raw material quality, delivery, and technical support
Collaborate with customers (internal and external) to understand requirements and improve product performance
Manage resources to optimize equipment, facilities, employees, methods, and materials
Ensure proper maintenance and calibration of foam pouring and fabrication equipment
Monitor equipment performance and coordinate with maintenance on preventive and corrective maintenance
Implement best practices for foam production, cutting, and fabrication processes
Demonstrate the company's core and growth values in the performance of all job functions
Model expected behaviors and hold team accountable to company values and standards