Lean Manufacturing & Trailer Assembly Transformation

JOB SUMMARY

The Production Manager leads all trailer assembly operations through Production Supervisors and is accountable for safe, high-quality, predictable output and the systematic transformation of how trailers are built. The role develops a stable production system built on one-piece flow, balanced work content, standardized work, quality at the source, visual management, and disciplined daily problem solving. The Manager converts the production schedule into an executable operating plan, develops frontline leaders, and partners with Materials, Quality, Engineering, Maintenance, and other support functions to eliminate constraints and sustain measurable gains.

REPORTING RELATIONSHIP

Reports to: Plant Manager | Direct reports: Production Supervisors and assigned production leadership

KEY RESPONSIBILITIES

Own production execution and plantwide flow

• Translate the master build schedule into daily and weekly production plans that align labor, station capacity, tooling, work instructions, and material readiness across all assembly areas.

• Lead a consistent daily management cadence: supervisor huddles, plan-versus-actual reviews, visible escalation of abnormalities, and timely recovery actions for shortages, downtime, quality issues, and staffing gaps.

• Use measured station cycle times, takt requirements, capacity analysis, and work-content balance to reduce bottlenecks, trailer waiting time, excessive work-in-process (WIP), and variation between stations.

• Coordinate trailer sequence, staffing changes, and recovery priorities with Planning and Materials; communicate realistic production commitments and risks to the Plant Manager.

Design and sustain the lean manufacturing system

• Own a practical lean transformation roadmap from departmental, batch-oriented work toward repeatable, one-piece trailer flow; define milestones, responsible owners, and verified performance improvements.

• Establish station-level standard work with supervisors and Engineering, including safe task sequence, target cycle time, labor content, required tools/materials, in-process quality checks, and transfer criteria.

• Implement and sustain 5S, point-of-use material delivery, FIFO, clear WIP controls, line-side visual management, and other methods that make normal and abnormal conditions immediately visible.

• Lead cross-functional kaizen and root-cause problem solving; validate countermeasures at the point of work, document new standards, and audit sustainability rather than relying on one-time fixes.

• Develop the operational capacity roadmap needed to support the plant’s future-state goal of 15 trailers per production day, based on validated cycle times and approved labor, material, equipment, and quality capabilities.

Lead safety, quality and operating performance

• Hold supervisors accountable for safe work, hazard identification, proper PPE, equipment safeguards, safe trailer access, and prompt corrective action.

• Partner with Quality to establish quality-at-the-source checks, defect containment, first-pass quality improvement, and permanent corrective action on recurring assembly defects and rework.

• Own production labor deployment, overtime control, labor hours per trailer, schedule attainment, station performance, and accurate reporting; use trends to improve productivity without compromising safety or quality.

• Make the shop floor the primary management workplace: observe actual assembly work, verify standards, coach problem solving, and remove systemic barriers to performance.

Develop supervisors and a capable workforce

• Set clear responsibilities and measurable expectations for Production Supervisors; coach them to lead daily flow, train to standard, solve problems at the source, and build accountable teams.

• Maintain succession, onboarding, cross-training, and skills-matrix plans so labor can be deployed flexibly without losing process discipline or workmanship.

• Build a respectful, high-trust operating culture in which employees raise concerns early, improvement ideas are acted upon, and performance or conduct issues are addressed fairly and promptly.

Coordinate cross-functional improvements and investments

• Work with Materials, Purchasing, Planning, Quality, Engineering, and Maintenance to establish reliable material presentation, equipment availability, engineering change readiness, and clear escalation paths.

• Identify tooling, fixtures, ergonomic improvements, automation, and capital needs; develop operational justifications based on capacity, labor savings, safety, quality, and payback, and support implementation and commissioning.

PERFORMANCE EXPECTATIONS

Performance is evaluated against targets set with the Plant Manager, including: trailers completed versus daily/weekly plan; readiness and schedule attainment; station cycle time versus takt; output and capacity improvement; labor hours per trailer and overtime; first-pass quality and rework; WIP and production interruptions; safety and corrective-action closure; standard-work adherence; and supervisor/employee training progress. The Manager is accountable for a visible improvement plan with documented results and sustained operating controls—not output achieved through chronic expediting or excessive overtime.

KNOWLEDGE, SKILLS & ABILITIES

• Demonstrated ability to lead lean change in a labor-intensive assembly environment; practical command of standard work, line balancing, takt/cycle-time analysis, one-piece flow, 5S, visual management, and structured root-cause problem solving.

• Strong knowledge of production planning and labor capacity, assembly drawings and specifications, quality controls, tooling/fixture needs, and industrial safety; trailer or heavy-equipment assembly knowledge preferred.

• Effective coaching, conflict resolution, cross-functional coordination, data interpretation, and written/verbal communication; competent with Excel and production/ERP reporting systems.

EXPERIENCE & EDUCATION

• Five or more years of progressive manufacturing/assembly leadership experience, including experience directing supervisors or multiple production areas, preferred.

• Documented results improving throughput, labor efficiency, product quality, or flow through people-centered process improvement strongly preferred.

• Bachelor’s degree in Operations, Manufacturing, Engineering, or a related field preferred; equivalent hands-on manufacturing leadership experience considered.

PHYSICAL & WORK ENVIRONMENT

Frequent presence on the production floor, with extended walking and standing; occasional bending, climbing stairs or approved access equipment, and movement in or around trailers. Exposure to industrial noise, seasonal heat, and changing production demands. Essential functions may be performed with reasonable accommodation, as applicable.