Operations Manager

PSW Group•Bellevue, OH

11d•Onsite

About The Position

PSW Group is hiring an Operations Manager to establish operational readiness and lead safe, reliable, cost-effective operations at its Advanced Casting Technology Development Center. The center will develop high-pressure and vacuum die casting, semi-solid casting, and other aluminum and magnesium casting technologies for automotive, aerospace, consumer electronics, and other light-metal industries. The role will support startup, development trials, prototype builds, and production programs as they are introduced. The Operations Manager reports to the senior leader responsible for the center and directly supervises assigned production supervisors, operators, and technicians. The position coordinates with Engineering, Plant Management, Maintenance, HR, and Supply Chain to meet schedules and operating targets. It begins with an 18-month assignment in Bellevue, Ohio, followed by a permanent base in Chicago, Illinois, with travel to support project needs. Travel may be up to 50%, including domestic and international project sites.

Requirements

Demonstrated experience managing manufacturing teams and delivering measurable improvements in safety, quality, delivery, productivity, and cost.
Experience developing supervisors, technicians, and operators.
Understanding of casting operations or plastic injection and supporting equipment, including casting cells, furnaces, tooling, and automation.
Ability to lead operational troubleshooting and engage specialists when needed.
Experience translating production or project requirements into staffing, capacity, and execution plans; managing operating costs; and using performance data to drive corrective action.
Experience establishing standard work, operator training, skills qualification, and disciplined daily management routines.
Working knowledge of process control, root-cause analysis, corrective action, and continuous improvement methods.
Ability to interpret operating data and support process capability and validation activities.
Understanding of manufacturing safety and environmental requirements in hot metal-forming operations, including risks associated with molten metal, equipment, and material handling.
Ability to work in Bellevue, Ohio, for the first 18 months and relocate to a permanent position in Chicago, Illinois, afterward.
Strong communication, organizational, analytical, and problem-solving skills.
Ability to prioritize, delegate, and coordinate work across technical and support functions.
Proficiency with Microsoft Office and manufacturing scheduling, reporting, or maintenance management systems.

Nice To Haves

Experience starting up or expanding a casting facility, pilot operation, or technology development center, including equipment commissioning and new program launches.
Experience managing HPDC aluminum or magnesium casting foundries.
Familiarity with ISO 9001, IATF 16949, control plans, PPAP, and customer-specific quality requirements relevant to assigned programs.
Ability to interpret casting simulation results and contribute to tooling, gating, venting, and process reviews.
Direct experience with MAGMA, FLOW-3D, die design, or robot programming.
Formal training in manufacturing, engineering, operations management, or a related field, or equivalent relevant experience.

Responsibilities

Lead the center’s operational readiness plan, including staffing, training, documentation, equipment readiness, launch milestones, and tracking startup risks and open actions.
Define operating requirements for casting machines, furnaces, robotics, and auxiliary equipment; participate in layout, material flow, installation, commissioning, and acceptance reviews.
Build and qualify the operating team before equipment and program launches; confirm readiness of work instructions, safety procedures, tooling, materials, maintenance access, and support resources.
Coordinate development trials and prototype builds with R&D and Engineering, provide trained personnel and available equipment, capture results, and incorporate approved lessons into repeatable practices.
Participate in design-for-manufacturing reviews and provide production input on casting feasibility, tooling access, handling, cycle time, staffing, and maintainability.
Support Engineering-led process development, capability studies, and validation.
Own the production part approval process (PPAP), including submission planning, documentation, production records, trial execution, evidence of process capability and operational readiness, customer approvals, and launch-action closure.
Direct daily casting operations to meet safety, quality, delivery, and cost objectives; translate project and customer requirements into daily and weekly operating plans.
Plan staffing, machine capacity, shift coverage, and work assignments; coordinate trial and production priorities and resolve competing demands on equipment and personnel.
Execute operating schedules, identify constraints, escalate resource gaps, and implement recovery plans for missed output or milestones.
Lead daily performance reviews and shift handoffs, assign corrective actions, set completion dates, and verify resolution of recurring operating problems.
Establish and improve measures including schedule attainment, throughput, first-pass yield, scrap, rework, downtime, labor productivity, and OEE; report results and recovery actions to management.
Manage labor utilization, overtime, consumables, and controllable operating costs within approved budgets; develop staffing and capacity forecasts and recommend investments.
Recruit, onboard, coach, and evaluate assigned staff with HR; maintain skills matrices, training plans, and qualification records; develop supervisors and technicians and address performance issues.
Implement standard work, approved operating procedures, workplace organization, and continuous improvement activities; improve flow, changeover time, equipment utilization, and process consistency.
Maintain a safe and orderly operating environment; enforce safety and environmental procedures, ensure required training, and address hazards, incidents, and unsafe practices.
Own tooling readiness and performance, including requirements, supplier coordination, design reviews, acceptance, maintenance planning, and corrective actions.
Work with Engineering on process development, tooling and automation design, process validation, and approval of technical changes; ensure operators follow approved settings and change-control requirements.
Own the quality management system, customer quality requirements, PPAP submission governance, and product acceptance and release; lead control-plan implementation, containment, and corrective actions with Quality and technical support.
Assign work and adjust staffing and schedules within approved plans; authorize overtime and operating purchases within delegated limits; recommend hiring, capital spending, and capacity changes for approval.
Stop work for unsafe conditions and pause affected operations when process control or product conformity is in doubt; secure the area or material and coordinate restart with the appropriate technical, Quality, or EHS owner.
Escalate unresolved risks, cross-functional resource conflicts, and decisions outside delegated authority; perform other related duties assigned by the direct supervisor.