Plant Manager

ABOUT US

XCAL Tools' South Point, Ohio facility is a diverse manufacturing operation specializing in forging, machining, fabrication, heat treatment, and other value-added manufacturing processes. Our capabilities support customers across mining, construction, railroad, industrial, and other markets throughout the United States and internationally.

The South Point operation combines traditional manufacturing expertise with continued investment in modern CNC machining, automation, tooling, equipment, and process improvement. We are seeking a proven leader to take overall responsibility for the performance of the facility and continue developing the people, processes, and systems needed to support our growth.

POSITION OVERVIEW

The Plant Manager is the senior operational leader for the South Point facility and is responsible for the overall performance of the plant, including safety, people, quality, production, delivery, financial performance, inventory, equipment, and continuous improvement.

This position requires a strong, hands-on leader who can develop people, establish accountability, understand the financial drivers of the business, and translate operational performance into measurable results.

While experience in machining, forging, or metal manufacturing is beneficial, we are equally interested in accomplished leaders from other manufacturing or industrial environments who have demonstrated the ability to lead complex operations, develop high-performing teams, understand financial performance, and deliver sustainable results.

The Plant Manager reports directly to the VP of Operations and works closely with Engineering, Quality, Safety, Finance, Sales, Human Resources, Supply Chain, and other XCAL locations.

JOB QUALIFICATIONS:

• Bachelor's degree in Business, Engineering, Operations Management, Manufacturing, or a related discipline preferred.Significant relevant leadership experience may be considered in place of a four-year degree.
• Prior experience as a Plant Manager in manufacturing, machining, forging, fabrication, metals, automotive, heavy industrial, mining-related manufacturing, or similar operations is beneficial.
• Knowledge of Lean Manufacturing, 5S, Kaizen, Six Sigma, or other continuous improvement methodologies preferred.
• ISO 9001 experience is beneficial.
• Experience with ERP/MRP systems and production management systems preferred.
• Strong computer skills, including Microsoft Excel and other business/operational reporting tools.
• Demonstrated success leading people and delivering measurable results in a manufacturing, industrial, distribution, operations, or similarly complex environment.
• Progressive leadership experience with responsibility for multiple departments, functions, or a significant operating unit.
• Proven ability to build teams, develop leaders, establish accountability, and improve organizational performance.
• Track record of successfully leading through change, solving complex problems, and improving results.
• Strong financial and business aptitude with the ability to understand and manage budgets, costs, operational variances, KPIs, and plant financial performance.
• Ability to interpret financial and operational information and translate data into actions that improve performance.
• Strong analytical, decision-making, and problem-solving skills.
• Experience with P&L responsibility, budgeting, forecasting, cost management, or similar financial accountability strongly preferred.
• Direct machining, forging, or metalworking experience is preferred but is not required. Proven leadership ability, business judgment, financial aptitude, and a demonstrated record of operational success will receive strong consideration.

ESSENTIAL JOB DUTIES:

Leadership & People Development

• Provide overall leadership and direction for the South Point facility and its departmental leadership team.
• Build a culture centered on safety, accountability, teamwork, communication, continuous improvement, and respect.
• Lead, coach, mentor, and develop managers, supervisors, and other key employees while building a strong leadership pipeline throughout the facility.
• Establish clear expectations and hold leaders accountable for performance while ensuring they have the support and resources necessary to succeed.
• Maintain a visible presence throughout the operation and develop strong working relationships with both salaried and hourly employees.
• Participate in recruiting, selection, onboarding, training, performance management, and workforce planning.
• Promote employee engagement, cross-training, development, and retention.

Operational Performance

• Direct all day-to-day plant operations to safely meet customer requirements for quality, delivery, and cost.
• Establish and monitor key performance indicators related to safety, quality, productivity, labor utilization, downtime, throughput, delivery, scrap/rework, inventory, and financial performance.
• Use operational and financial data to identify performance gaps, establish priorities, and drive corrective action.
• Ensure production schedules, staffing, equipment, materials, and other resources are aligned with customer demand and business priorities.
• Work closely with Production, Engineering, Maintenance, Quality, Inventory, and other functions to remove constraints and improve overall plant performance.
• Drive continuous improvement in productivity, equipment utilization, workflow, scheduling, setup reduction, process reliability, and capacity.

Financial & Business Management

• Assume responsibility for the financial performance of the facility, including operating expenses, labor, material usage, inventory, recoveries, margins, and overall profitability.
• Develop a strong understanding of the plant P&L and work closely with Finance and the VP of Operations to identify and address financial performance opportunities.
• Participate in annual budgeting, forecasting, capital planning, and cost-reduction initiatives.
• Monitor actual performance against budgets, forecasts, standards, and operational targets and take corrective action when necessary.
• Understand the relationship between labor, machine time, material, overhead, production efficiency, inventory, and product cost.
• Support accurate job costing, routings, production standards, and quoting through reliable operational data and feedback.
• Evaluate capital equipment and facility needs, develop business justifications, and oversee approved projects through successful implementation.
• Manage plant resources with an ownership mindset and focus on sustainable profitability rather than short-term results.

Safety & Compliance

• Provide visible leadership for the plant's safety culture and ensure safety remains the first consideration in operational decisions.
• Ensure compliance with OSHA requirements, company policies, established procedures, and applicable regulatory requirements.
• Support incident investigations, corrective actions, safety audits, training, and proactive identification of workplace hazards.
• Hold all levels of the organization accountable for maintaining a safe workplace.

Quality & Customer Performance

• Ensure products are manufactured in accordance with customer specifications, quality standards, and established processes.
• Promote a culture in which quality is built into the manufacturing process rather than inspected into the finished product.
• Monitor customer complaints, internal nonconformances, scrap, rework, and other quality indicators and ensure effective corrective actions are implemented.
• Support ISO 9001 requirements and continuous improvement of the facility's quality management system.
• Partner with Sales and other functions when operational involvement is required to support customers, new products, or business opportunities.

Inventory, Equipment & Facility Management

• Maintain appropriate controls over raw materials, work-in-process, finished goods, tooling, and other plant inventory.
• Drive inventory accuracy, timely transaction processing, proper job closure, and effective material management.
• Ensure maintenance resources and preventive maintenance programs support equipment reliability and production requirements.
• Identify equipment, tooling, technology, automation, and facility improvements that improve safety, capacity, quality, efficiency, or profitability.
• Ensure the facility and production areas are maintained to appropriate standards of organization, cleanliness, and operational readiness.

Continuous Improvement

• Establish a culture of continuous improvement throughout the facility using data, employee involvement, root-cause problem solving, and appropriate Lean manufacturing principles.
• Identify and eliminate waste, unnecessary cost, bottlenecks, downtime, inefficient processes, and other barriers to performance.
• Lead initiatives involving 5S, visual management, workflow improvement, standard work, process optimization, and other appropriate continuous improvement methods.
• Encourage employees at all levels to identify opportunities and participate in improving the operation.
• Share and implement best practices across XCAL operations where appropriate.

*Excellent benefits include medical with a standard PPO plan with deductibles as low as $1,500 and wellness credit up to $750; free concierge primary care; voluntary 401k plan currently matching up to 12%; voluntary dental and vision plans; free telemedicine services; basic life, long and short-term disability coverage.

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