Sr Manufacturing Manager - Plastics

Terumo BCT, Inc. • Denver, CO

1d • $148,500 - $185,600 • Onsite

About The Position

This role sets the strategic vision and drives systemic improvements in efficiency, quality, safety, cost, and employee engagement for a highly technical plastics manufacturing operation. The Sr. Manufacturing Manager is responsible for leading a multi-process, multi-shift operation including injection molding, medical tubing extrusion, and manual/benchtop assembly operations. This leader will ensure operational excellence through strong execution of performance management systems, deep technical engagement with process engineering, and ownership of key manufacturing financial drivers. The role requires a strong balance of technical plastics expertise, financial acumen, and people leadership capability to deliver consistent, high-quality output in a 24/5 manufacturing environment.

Requirements

• Bachelor’s degree or an equivalent of education and experience sufficient to successfully perform the essential functions of the job may be considered.
• Minimum 10+ years of manufacturing experience, with at least 5+ years in leadership roles
• Demonstrated leadership in plastics manufacturing environments, including: Injection molding (required or strongly preferred)
• Extrusion (highly preferred)
• Experience managing multi-shift operations (24/5 or 24/7)
• Proven track record of improving OEE, labor efficiency, and scrap performance
• Experience working in regulated environments (medical device preferred)
• Strong financial acumen, including: Understanding of manufacturing cost structures, absorption, and variances
• Ability to partner effectively with Finance
• Deep understanding of: OEE systems and loss analysis
• Labor efficiency and productivity models
• Demonstrated ability to lead complex, multi-process manufacturing operations
• Exceptional leadership, coaching, and organizational development skills
• Strong problem-solving and continuous improvement capability
• Effective communication skills across all organizational levels
• Proficiency in manufacturing systems and data analysis tools or an equivalent competency level acquired through a variation of these qualifications may be considered.
• Experience / strength in the use of SAP preferred.

Nice To Haves

• Master’s degree preferred.
• Lean / Six Sigma certification (Green Belt or higher) strongly preferred
• Cross-functional experience (Quality, Engineering, Supply Chain, or Finance) a plus

Responsibilities

• Lead, coach, and develop a large multi-shift organization consisting of supervisors, leads, and operators across multiple manufacturing processes
• Build leadership capability within frontline supervision through mentoring, accountability systems, and talent development
• Ensure consistent execution across all shifts through structured communication, standard work, and escalation processes
• Ensure labor resources are aligned with the supply plan and customer demand daily and monthly.
• Lead daily, weekly, and monthly performance review meetings driven by KPI data
• Foster strong cross-functional relationships with Engineering, Quality, Finance, Supply Chain, and CI teams
• Proactively communicate operational performance, risks, and improvement plans to plant leadership
• Lead performance across injection molding, extrusion, and assembly operations, ensuring alignment to production, quality, and cost targets
• Own and improve key operational metrics, including: OEE (availability, performance, quality), Labor efficiency / productivity, Scrap and yield performance
• Develop and execute strategies to reduce downtime, improve throughput, and optimize labor utilization
• Champion Lean Manufacturing and Continuous Improvement initiatives across the operation
• Utilize data analysis to identify trends, losses, and improvement opportunities
• Partner with CI teams to implement sustainable process improvements and track results
• Develop annual production budgets and manage performance against key financial metrics
• Own and drive improvements in: Labor efficiency and absorption, Scrap and material cost, Headcount and variable spend
• Partner directly with Finance to analyze variances (labor, scrap, efficiency, overhead), validate routing structures and cost assumptions, translate operational performance into financial outcomes, and align production teams to plant financial goals with clear accountability at all levels
• Work closely with Process Engineering to identify and prioritize improvement opportunities, validate process changes using production and financial data, and support new product introductions and new line startups (including extrusion)
• Lead structured problem-solving efforts using tools such as root cause analysis, DMAIC, and statistical methods
• Utilize SPC and process capability data to improve process control and drive project pipelines
• Ensure compliance with GMP, GDP, and applicable regulatory standards
• Maintain and improve quality performance by monitoring key metrics and driving corrective actions
• Partner with Quality on non-conformance investigations and CAPA execution
• Drive implementation and sustainment of 6S and visual management systems
• Act as a subject matter expert for plastics manufacturing processes
• Act as the Voice of the Customer and Subject Matter Expert for processes and partnerships within the business.
• Lead safety performance by setting expectations, monitoring metrics, and driving continuous improvement
• Ensure all incidents are reported, investigated, and addressed appropriately
• Build a culture of accountability and engagement across all levels of the organization
• Drive adherence to training requirements, policies, and standard operating procedures
• Possess the ability to coach and develop supervisors and front-line leaders to improve quality, production and safety.
• Foster a continuous improvement mindset amongst employees by proactively seeking input and feedback on manufacturing processes and procedures.
• Ensure the production team’s adherence to safety procedures and 6S protocols.
• Solicit feedback from employees regarding safety improvements on a regular basis.

Benefits

• competitive total reward offerings that consist of compensation, benefits, recognition, along with a wealth of other well-being, work-life and recognition programs
• multiple group medical, dental and vision plans
• a robust wellness program
• life insurance and disability coverages
• a variety of voluntary programs such as group accident, hospital indemnity, critical illness, pet insurance and much more.
• 401(k) plan with a matching contribution
• vacation and sick time programs

What This Job Offers

• Job Type: Full-time
• Career Level: Manager