Director of Manufacturing

The Director of Manufacturing is responsible for ensuring that NK’s manufacturing team, facilities, sourcing and logistics capabilities allow us to meet our customers’ needs with exceptional products delivered on time. We are in growth mode and our operations must continue to scale – from people to plant – to support the growth and profitability of the company. This position calls for a leader who can deliver while continually improving our people and our processes with a focus on Lean and 6S methodologies. The Director of Manufacturing oversees the largest team at NK and developing the entire manufacturing team into multi-skilled growth-minded contributors is a critical part of this role. This position is based at our Pennsylvania headquarters, overseeing operations in that location as well as supporting our other locations. The Director of Manufacturing reports directly to the COO. NK views manufacturing as a critical and valuable part of our DNA and is committed to continuing to grow in our capacity and capabilities.

Building upon a foundation of over 45 years of product and customer service excellence, NK remains a dynamic growth company with an entrepreneurial spirit. We are growing both organically and through acquisition. Working at NK offers excellent opportunities for personal and professional development as well as the fun and satisfaction of being part of a successful American business. Nielsen-Kellerman is an Equal Opportunity Employer and former military service members are encouraged to apply. This is at-will employment.

Essential Duties & Responsibilities 

Manufacturing

• Oversee all manufacturing and supporting activities in Boothwyn, PA, including: material sourcing, PCBA assembly, finished goods assembly, product packaging, manufacturing engineering, and quality control.
• Ensure that we produce quality product, available to ship to customers on time.
• Ensure manufacturing documents, including BOMs and SOPs, are accurate, up-to-date, effective and used. 
• Be responsible for the selection, purchase, maintenance, repair and replacement of all capital equipment required in the manufacturing operation.
• Create and maintain visual metrics which drive production improvements.
• Maintain systems for production scheduling.
• Work closely with sales team to develop and update forecast and set finished goods policies and stocking levels.
• Manage staffing to meet demand while not relying on excess overtime.
• Be the champion of quality in everything we do and produce. Encourage team members to learn and use Lean manufacturing quality tools: Lean manufacturing, andon system, ECO system, 6 Sigma. 6S.
• Work closely and effectively with other staff teams including Fulfillment, Engineering, Product Management, Sales and Marketing, Accounting and Human Resources.

Materials & Logistics

• Ensure materials purchases seamlessly support manufacturing while minimizing excess inventory.
• Ensure Kanban system – both digital and card-based – is kept up to date and accurate to ensure timely purchase of materials.
• Oversee the purchasing team in vendor management and costing and purchase quantity decisions.
• Manage periodic cycle counts and annual inventory counts.

New Product Development

• Direct the active participation of the manufacturing team in the development of NK’s new products, helping to ensure they are designed for efficient and effective assembly in NK’s manufacturing environment.
• Oversee the creation and documentation of new product test and assembly procedures and production lines.

Acquisitions

• Support the M&A activities of the company by assisting in the evaluation of acquisition targets with respect to their manufacturing and operational aspects.
• Oversee relocation, integration and/or manufacturing development as it relates to acquisitions.

Facilities

• Use production and support space efficiently, while also anticipating space needs for company growth. 
• Plan for and oversee facilities expansion and upgrades as needed.

People

• Oversee hiring and training of all manufacturing, materials and support personnel.
• Recommend staffing changes to support growth.
• Ensure staffing levels and production schedules are sufficient to meet customer demand.
• Ensure all employees are continuously developing their skills and cross-training to expand their value to the company and their sense of achievement and engagement. 
• Conduct Kaizen and other improvement activities that also serve to develop employee’s problem-solving muscle and teamwork.
• Teach, live and lead according to Lean principles. Make them a part of everyday life in every part of the operation rather than siloed improvement initiatives.
• Administer skills-based compensation and training system. Supervise bi-annual skills matrix evaluation and recommend compensation programs and individual salary adjustments.

This is not an exhaustive list of the job duties to be performed. Based on the needs of the company, an employee in this position may be required to fulfill other job-related duties at the direction of their manager.

Personal Qualities for Success in this Job

• A willingness and ability to learn new things and expand responsibilities. Takes the initiative, asks questions, researches independently, and retains new information.
• Strong ethical conduct and integrity, proactive problem resolution mindset, and drive and passion to get things done.
• Teacher, collaborator and communicator. Believer in servant leadership.
• Excellent communication, people management and reporting/analytical as well as decision making skills.
• Ability to effectively communicate urgency without rushing and motivate the development of good work habits.
• Ability to have the crucial conversations and address performance problems fairly and effectively. 

Specific Skills & Competencies

Required

• Deep experience-based knowledge of manufacturing as well as Lean and 6 Sigma methodologies.
• Understanding of manufacturing operations P&L and balance sheet interactions and cash flow.
• Ability to use and customize integrated ERP system.
• Comfort with Microsoft Excel, including use of ODBC or SQL queries, pivot tables and charting.
• Ability to identify financial risks and opportunities to enhance the profitability of the company.
• Knowledge of OSHA safety regulations.
• General engineering problem solving skills.
• Can read, speak and understand English fluently.

Desired

• Electronics manufacturing knowledge and experience.
• Surface mount technology, component and machine placement knowledge and experience.
• Knowledge of injection molded plastic parts – materials, assembly properties and quality issues.
• Knowledge of manufacturing adhesives, cable harness assembly and electro-mechanical box builds.
• Basic electrical engineering knowledge and trouble-shooting abilities.

Required Education & Experience

• BA/BS degree in related field.
• 10+ years in leadership roles in a manufacturing environment, preferably in electronics.
• 5+ years experience managing significant teams of direct and indirect reports.
• Formal or informal education and extensive experience in Lean methodologies.
• Demonstrated success leading in a fast-paced manufacturing industry.
• Demonstrated ability to lead and inspire diverse teams to achieve challenging goals.

Supervisory Responsibilities

This position is responsible for the direction and development of a large and diverse team. This position has oversight of the entire manufacturing and facilities management team with direct supervision of production supervisors, manufacturing engineers and materials staff as well as indirect oversight of 50+ electronics assemblers. Leading, managing and developing people is at least half of this job. NK is a non-union workplace.

Work Environment and Physical Demands

Climate-controlled indoor manufacturing plant and offices. Must be able to work at a computer for 6 hours per day with reasonable accommodations. May occasionally be required to stoop, kneel, crouch or crawl, climb or balance and lift and/or drag up to 50 pounds. Dogs may be present in office.

Hours of Work / Work Location / Travel

The company operates out of an industrial park building located in Boothwyn, PA. Manufacturing hours are Monday through Thursday, 6:30 to 5:00. The Director of Manufacturing is expected to be available in the plant Monday - Thursday to provide leadership and guidance to the manufacturing team for the majority of these hours, however a limited amount of work-from-home hours may be accommodated. Occasional travel to subsidiary locations will be required.

Training

Most training is on-the-job with additional formal training provided as appropriate. NK supports continuing professional education directly and also provides tuition support for relevant degree programs.

Pay Rate / Salaried position

This is an exempt position. Annual salary will depend upon prior experience and demonstrated skills. Annual bonus based on company performance. 

Benefits

• Fully paid employee benefits include medical, dental, vision, disability and life insurance
• Voluntary benefits include family medical, life insurance, critical care insurance, FSA dependent care and pet insurance
• Paid Maternity/Paternity Leave 
• HSA with employer contribution 
• 401k with employer match to 5% after 90 days. 
• 9 paid holidays, and flexible PTO

All benefits are subject to a benefit waiting period of 60 to 90 days.

Work Authorization/Security Clearance

Must be eligible to work in the US without employer sponsorship. Security clearance is not required.

Equal Opportunity Employer

NK is an equal opportunity employer. NK conducts all employment-related activities in full compliance with all applicable Federal and State laws and without regard to an individual’s age, color, gender, disability, marital status, national origin, citizenship, race, religion, sexual orientation, veteran status, or other legally protected category. No person will be discriminated against in hiring or in any other aspect of their employment including training, transfer, promotion, compensation, benefits, and all other aspects of employment. Reasonable accommodation will be made to enable individuals with disabilities to perform the essential functions of this position. 

About NK

Nielsen-Kellerman is the parent company for eight brands focused on helping people succeed in their profession or passion by providing mission-critical measurements, information, insight, and guidance whenever and wherever needed. Ambient Weather, Kestrel Weather, KestrelMet, RainWise, Kestrel Ballistics, MagnetoSpeed, Blue Ocean Megaphones and NK Sports are each recognized as the preeminent products for their applications from meteorology to military, firefighting to farming and rowing to research. Our products ARE us - we design them, build them, sell them, and passionately stand behind them. 

NK has been in business for over four decades and is still growing stronger. Working here offers excellent opportunities for personal and professional development as well as the fun and satisfaction of being part of a successful American business. NK is a Lean enterprise committed to American manufacturing and continuous improvement of our design, production, administrative and sales processes.

NK's home office is located in Boothwyn, PA, about 30 minutes southwest of Philadelphia and our Ambient Weather brand operates primarily from Chandler, AZ in the Phoenix suburbs. NK's work environment is informal and high-energy, and our employees' quality of life is important to us. NK is proud to have been named a Philly Top Workplace eight out of the last ten years including 2023.