Senior Program Manager will be responsible for leading automation projects from concept to implementation across JBPCO's manufacturing sites. The project's life cycle includes, but is not limited to identifying automation opportunities, justifying, developing concepts, writing the scope of work, selecting the preferred vendor/integrator, business case development/presentation, design validation, ensuring the design & build follows JBPCO standards, and launching the solution at the plant. The Senior Program Manager will be executing multiple projects at one time, potentially in different facilities across North America that vary from welding chassis frames, laying fiberglass to machine tending to general assembly.
Essential Job Functions: - Lead and support manufacturing initiatives aimed at process improvements through the targeted implementation of automated processes that drive improvements in key corporate metrics for safety, quality, cost and throughput.
- Leads Concept-to-Commissioning process for automation systems, working with our internal manufacturing customers and the external system integrators.
- Help define better business processes that support the transformation and automation of JBPCO's manufacturing footprint.
- Drives cross-functional engagement and stakeholder alignment to advance key projects, strategies, and initiatives, including the formulation, justification, and presentation of capital investment (CapEx) proposals and business cases that support organizational objectives.
- Confers with planning and design staff concerning product design and tooling to ensure efficient Lean production methods.
- Confers with management, engineering, and other staff regarding manufacturing capabilities, production schedules, throughput ramp up plans, and other considerations to facilitate production processes.
- Leads cross-functional collaboration with subject matter experts to evaluate manufacturing requirements, develop innovative process solutions, assess project cost implications, and establish best-in-class manufacturing practices.
- Collaborate on the development and implementation of standardized work instructions, PFMEAs, and other control plans to ensure quality and consistency.
- Develop equipment specifications (RFQ) to meet manufacturing requirements, and negotiate for purchase of equipment, materials, or parts. Evaluate equipment according to specifications and quality standards through design reviews, and gated acceptance testing.
- Works with Business Units on production times, staffing requirements, and related costs to provide information for stakeholder decisions.
- Adheres to Quality policy by exceeding customer expectations, being customer focused and supporting continuous improvement activities.
- Adheres to JBPCO and industry safety policies and standards 100% of the time, including but not limited to, RIA, ANSI, ISO, IEEE, and NFPA.
- Execute internal concept development workshops with the manufacturing sites to define base project scope. Output to include, base process, automation selection, man-machine charts, cardboard mockups, cost estimates
- Utilize project management skills to maintain an appropriate level of project control with respect to project budget, project timeline, resource allocation, document control, and issuance of purchase orders.
- Create and maintain the required level of control with all JBPCO documents, included but not limited to, solid models, drawings, procedures, and work instructions.
- Leads design reviews, build validation, FAT and SAT with the supplier ensuring the full representation of JBPCO is integrated into the process.
- Delivers comprehensive project updates to leadership and cross-functional stakeholders, providing visibility into progress, risks, dependencies, and mitigation strategies to support informed decision-making
- Lead training efforts across the enterprise to enable manufacturing operations to be self-sufficient at running, maintaining, and modifying automation systems.
- Execute or assist vendors/integrators with standardized Task-Based Risk Assessment in accordance with A3 and JBPCO (ANSI/RIA TR R15.306).
- Work with maintenance on policies, procedures, and spare parts.
- Lead and train the Business Units on automation safety standards, mechanical and electrical.
- Coach and mentorship to junior engineers to help build internal capabilities on project management across the enterprise.
- Partner with site-level engineers, operations leaders, and corporate stakeholders to deploy best practices, standards, and advanced technologies.
- Conduct process capability analysis, time studies, and value stream mapping to identify and eliminate waste.
- Serve as a technical resource for new product introductions (NPIs), manufacturing cell designs, and layout optimization.
- Stay current with emerging manufacturing technologies (e.g., Industry 4.0, robotics, additive manufacturing) and assess their fit within the organization.
- Stay current with project management standards and technical skills to support and serve JBPCO's business units.
Qualifications: - A self-starter with strong project leadership experience.
- Has experience successfully leading projects transforming a traditional low volume/high mix manual manufacturing environment over to Automation.
- Proven ability to lead various sizes of manufacturing projects and drive measurable improvement in cost, quality, safety, or delivery metrics.
- Experience with various types of automation, automation vendors, and automation applications.
- Experience working in a high-volume, complex manufacturing environment and/or high-mix, low volume manufacturing environment.
- Ability to communicate, collaborate, and build rapport with personnel at all levels in a manufacturing environment.
- Understanding of manufacturing design elements/tools/systems, processes, and regulatory requirements.
- Understanding of design principles such as Data Analysis, DOE, FMEA, DFM/DFA.
- Must possess excellent automation/electrical/mechanical aptitude.
- Ability to work collaboratively within a team as well as independently.
- Must have a passion and strong working knowledge for safety, workplace organization, and continuous improvement with a focus on Lean Manufacturing, Six Sigma, and Lean implementation.
- Proficient with computer systems and software packages such as Microsoft Word, Excel, PowerPoint, Outlook (email), Microsoft Project or Smartsheet, and JD Edwards.
- Optional: 3D CAD Competency (SolidWorks, Draftsite or similar software preferred).
- Optional: Visual Basic Programming, Ladder Logic, or other programming knowledge.
Education:- BSME, BSIE, BSEE or equivalent.
- Ten years or more of directly related experience in a manufacturing engineering or advanced manufacturing role, preferably in a multi-site or complex manufacturing environment. A minimum of five years must be in program/project leadership.
- Preferred: Certifications in PE, Lean Six Sigma, PMP, or relevant engineering credentials.
Travel Expectation: - 35-50%.
- Must have a valid driver's license and passport.
