We are seeking a strategic and results-driven Sr. Director of Operations to lead the performance of multiple manufacturing facilities across a regional network. This role is responsible for driving operational excellence across safety, quality, sustainability, customer centricity, and cost control. The ideal candidate is a proven operations leader with deep expertise in manufacturing, a passion for continuous improvement, and a track record of building inclusive, high-performing teams. You will serve as a key architect of operational strategy and execution, shaping the future of manufacturing excellence through smart factory methodologies and digital transformation.
Position Responsibilities
Operational Excellence and Continuous Improvement
- Lead and mentor regional leadership teams in financial performance and KPI drivers
- Champion lean, Six Sigma, and WCM initiatives to enhance productivity and reduce costs
- Oversee all manufacturing pillars, including supply chain, engineering, maintenance, and production, driving cost deployment and process improvements
Employee Engagement and Development
- Foster an inclusive, empowered culture built on collaboration, trust, and shared goals
- Align plant objectives with overall business strategy, enhancing cross-functional communication
- Collaborate with HR to implement workforce development plans that support skill growth and agility
- Guide community relations to maintain positive brand presence in plant communities
EHS and Risk Prevention
- Promote a safety-first culture, emphasizing 5S, housekeeping, and proactive risk identification
- Ensure full compliance with internal and external EHS standards and regulations
- Drive continuous improvement in safety and environmental metrics through preventative programs
- Lead efforts to maintain highly protected risk ratings and safeguard assets across facilities
Finance and CAPEX Leadership
- Lead budget planning and forecasting processes for the region
- Partner with engineering to scope and prioritize capital investments across a multi-year horizon
- Monitor P&L metrics and performance reports, guiding teams toward financial objectives
- Ensure projects align with company financial strategy and compliance requirements
Prerequisites
- Bachelor’s degree in a technical or business discipline
- 10+ years of progressive experience in manufacturing operations
- Demonstrated results in people leadership, change management, and strategic execution
- Experience managing union and non-union environments
- Background in gypsum, finishing, or similar continuous process industries preferred
- Proven capital project management experience ($5M–$20M scale)
- Ability to travel up to 50% across multiple U.S. manufacturing sites
Certifications (Preferred, but not Required)
- Lean Six Sigma Black Belt or equivalent
- Certified Safety Professional (CSP)
- PMP or CAPEX project management certifications
What the Role Offers
- Salary: $180,000 – $220,000
- Employment Type: Full-Time
- Permanent Placement Fee: 23%
- Leadership of a $700M+ revenue operation with a $387M COGS responsibility
- Oversight of 9 manufacturing plants, 800+ employees, and $300M in assets
- Direct influence over plant safety, quality, productivity, and digital transformation
- A chance to shape smart factory initiatives and lead industry innovation
Why Malvern?
Malvern serves as a strategic hub for forward-thinking manufacturing leadership, where innovation, sustainability, and digital integration converge. This role positions you at the forefront of transforming traditional operations into smart, agile, and customer-centric environments. With support from a collaborative executive team and access to cutting-edge tools and methodologies, Malvern offers the ideal setting to drive impactful change while fostering a culture of excellence and continuous learning.