Manufacturing - Assembly Project Leader

POSITION OVERVIEW:

The Manufacturing Assembly Process Project Leader is responsible for establishing and implementing the assembly processes required for the successful startup and ongoing operation of a new BAC manufacturing facility. This role leads the development of plant flow, standard work in process (SWIP), GAS compliance, scheduling, and MRP practices while building the operational capabilities, workforce readiness, and management systems needed to support safe, efficient, and sustainable manufacturing performance. The position partners with Operations, Engineering, Quality, Supply Chain, Planning, EHS, Human Resources, and site leadership to establish operating standards, prepare the workforce, and deliver operational readiness aligned with BAC standards.

PRINCIPAL ACCOUNTABILITIES:

• Lead assembly process readiness for the greenfield plant from process design and layout validation through production launch, ramp-up, and stabilization. 
• Partner with Manufacturing Leadership, Human Resources, and Training teams to support workforce onboarding, training, certification, and operational readiness activities required to successfully launch and sustain production operations.
• Develop and validate end-to-end plant flow, material movement, work sequencing, workstation requirements, labor plans, and assembly methods that support safe and efficient operations. 
• Establish SWIP requirements and controls that support production flow, inventory visibility, quality, and schedule attainment. 
• Implement applicable GAS compliance requirements and confirm assembly processes, documentation, training, and controls meet established standards before startup. 
• Partner with Supply Chain, Planning, Operations, and Finance to establish scheduling and MRP processes, roles, master data requirements, and operating routines. 
• Develop assembly standard work, cycle-time expectations, quality checkpoints, visual controls, escalation processes, and performance measures. 
• Support process trials, pilot builds, readiness reviews, production ramp-up, issue resolution, and corrective action activities. Coordinate cross-functional dependencies involving layout, equipment, materials, staffing, systems, quality, safety, and production planning. 
• Create and maintain standard operating procedures, work instructions, training materials, certification requirements, process maps, and other documentation needed for site execution. 
• Train and certify site manufacturing leaders and team members to execute, monitor, problem-solve, and sustain assembly processes to established standards. 
• Implement applicable BAC X standards and daily management practices, including tier boards, hour-by-hour monitoring, visual controls, standard work, and performance escalation. 
• Track workstream milestones, risks, decisions, dependencies, and deliverables; communicate status and escalate barriers that may affect operational readiness. 
• Transition ownership to site leadership with documented processes, trained and certified resources, confirmed operating routines, and clear accountability for sustaining performance. 
• Align with team and stakeholder for labor planning and productivity – operational labor standards, staffing models, variable labor planning, ramp up productivity targets
• Startup ramp plans to include pilot builds, ramp up plans, capacity milestones
• Leader standard work and daily accountability process development.

NATURE AND SCOPE:

This is a hands-on project leadership role responsible for the design, implementation, validation, and startup of assembly operations for a greenfield manufacturing facility. The incumbent leads the assembly process workstream and coordinates cross-functional resources without direct authority over all contributors. The role requires extensive engagement within manufacturing environments and the ability to integrate plant layout, material flow, workforce readiness, planning processes, systems, quality, and safety into a sustainable operating model. Success is measured by operational readiness, safe and efficient production flow, validated assembly processes, workforce capability, production performance, and a successful transition to site leadership.

REQUIRED KNOWLEDGE & SKILLS:

• Bachelor’s degree in manufacturing engineering, Industrial Engineering, Operations, Supply Chain, or a related field; equivalent relevant experience may be considered. 
• Minimum of 10 years of progressive experience in manufacturing engineering, assembly operations, industrial engineering, production planning, or manufacturing leadership. 
• Demonstrated experience designing, launching, and stabilizing assembly processes in a manufacturing environment; experience supporting greenfield manufacturing startup, major expansion, or significant operational transformation strongly preferred.
• Strong knowledge of plant flow, material movement, standard work, SWIP, production scheduling, MRP, capacity planning, and daily management practices. 
• Experience with process validation, pilot builds, production ramp-up, quality controls, problem solving, and continuous improvement. 
• Experience applying safety, regulatory, quality, and operational compliance requirements within manufacturing processes; experience with applicable GAS compliance preferred. 
• Ability to develop clear SOPs, work instructions, process maps, training materials, and certification standards. Proven project leadership skills, including planning, dependency management, risk identification, issue resolution, and cross-functional coordination. 
• Ability to train and influence manufacturing leaders and frontline teams while reinforcing accountability to established standards. 
• Strong communication, analytical, organizational, and decision-making skills. 
• Proficiency with ERP/MRP, production scheduling, manufacturing data, and Microsoft Office tools. 

WORKING CONDITIONS:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.  Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.  This role will entail significant domestic travel (up to 75% depending on location of applicant) and possible international travel may be required based on project activity and business needs.

BAC Hiring Compensation Range: $98400-$168900

BAC offers a comprehensive benefits package to include medical, dental, vision, paid time off, 401k, employee stock ownership plan, and more. Please see additional details on the BAC website at www.Baltimoreaircoil.com.  

BAC Employees are eligible to participate in an annual bonus incentive program.