Operations Manager PSW Group is a leading magnesium and aluminum manufacturer advancing nonferrous metal technologies. We are investing in a state-of-the-art Advanced Casting Technology Development Center to expand high-pressure and vacuum die casting, semi-solid casting, and other aluminum and magnesium casting technologies. The center will develop casting solutions for automotive, aerospace, consumer electronics, and other light-metal industries. We are seeking an experienced Operations Manager with high-pressure die casting (HPDC) knowledge and demonstrated manufacturing leadership. This role will establish operational readiness during startup and then lead safe, reliable, and cost-effective daily operations across development trials, prototype builds, and production programs as they are introduced. The role reports to the senior leader responsible for the center and directly supervises assigned production supervisors, operators, and technicians. It coordinates with Engineering, Plant Management, Maintenance, HR and Supply Chain to deliver agreed schedules and operating targets. The position begins with an 18-month assignment in Bellevue, Ohio. Following that assignment, the position will be permanently based in Chicago, Illinois, with travel to support project needs.
CORE RESPONSIBILITIES
Production Readiness - Startup & New Program Launch
- Lead the operational readiness plan for the center, with defined staffing, training, documentation, equipment readiness, and launch milestones. Track risks and open actions through startup and the transition to routine operations.
- Define operating requirements for new casting machines, furnaces, robotics, and auxiliary equipment. Participate in layout, material flow, installation, commissioning, and acceptance reviews with Engineering, Maintenance, and project owners.
- Build and qualify the operating team before equipment and program launches. Confirm that work instructions, safety procedures, maintenance access, tooling, materials, and support resources are ready for use.
- Coordinate development trials and prototype builds with R&D; and Engineering. Provide trained personnel and equipment availability, capture operating results, and turn approved lessons into repeatable operating practices.
- Participate in design for manufacturing reviews and provide production input on casting feasibility, tooling access, handling, cycle time, staffing, and maintainability. Support Engineering-led process development, capability studies, and validation.
- Own the production part approval process (PPAP), including submission planning, documentation, production records, trial execution, and evidence of process capability and operational readiness. Coordinate supporting inputs and customer approvals, and close launch actions before production release.
`Production & Team Management - Ongoing Operations
- Direct daily casting operations to meet safety, quality, delivery, and cost objectives. Translate approved project and customer requirements into achievable daily and weekly operating plans.
- Plan staffing, machine capacity, shift coverage, and work assignments. Coordinate trial and production priorities with Engineering and project stakeholders, and resolve competing demands on equipment and personnel.
- Execute the operating schedule; identify constraints early, escalate resource gaps, and implement recovery plans for missed output or milestones. Confirm readiness of materials, tooling, equipment, and trained personnel
- Lead daily performance reviews and shift handoffs. Assign corrective actions, establish completion dates, and verify that recurring operating problems are resolved.
- Establish and improve relevant measures such as schedule attainment, throughput, first-pass yield, scrap, rework, downtime, labor productivity, and overall equipment effectiveness (OEE). Report results and recovery actions to management; use trial-specific milestones during development work.
- Manage labor utilization, overtime, consumables, and controllable operating costs within approved budgets. Develop staffing and capacity forecasts and recommend investments supported by operating needs.
- Recruit, onboard, coach, and evaluate assigned staff in coordination with Human Resources. Maintain skills matrices, training plans, and qualification records; develop supervisors and technicians and address performance issues.
- Implement standard work, approved operating procedures, workplace organization, and continuous improvement activities. Lead practical improvements in flow, changeover time, equipment utilization, and process consistency.
- Maintain a safe and orderly operating environment. Enforce approved safety and environmental procedures, ensure required training, and promptly address hazards, incidents, and unsafe practices.
Functional Coordination & Decision Authority
- Own tooling readiness and performance, including tooling requirements, supplier coordination, design reviews, acceptance, maintenance planning, and corrective actions. Work with Engineering on technical process development, tooling and automation design, process validation, and approval of technical changes. Ensure operators follow approved process settings and change-control requirements.
- Own the quality management system, customer quality requirements, PPAP submission governance, and product acceptance and release. Lead implementation of control plans, containment of suspect product, and corrective actions, coordinating Quality resources and technical support as needed.
- Assign work and adjust staffing and schedules within approved plans; authorize overtime and operating purchases within delegated limits. Recommend hiring, capital spending, and capacity changes for approval by the responsible leader.
- Stop work for unsafe conditions and pause affected operations when process control or product conformity is in doubt. Secure the area or material and coordinate restart with the appropriate technical, Quality, or EHS owner.
- Escalate unresolved risks, cross-functional resource conflicts, and decisions outside delegated authority. Perform other related duties assigned by the direct supervisor.
QUALIFICATIONS
- Demonstrated experience managing manufacturing teams and delivering measurable improvements in safety, quality, delivery, productivity, and cost. Experience developing supervisors, technicians, and operators is required.
- Understanding of casting operations or plastic injection and supporting equipment, including casting cells, furnaces, tooling, and automation. Ability to lead operational troubleshooting and engage specialists when needed.
- Experience translating production or project requirements into staffing, capacity, and execution plans; managing operating costs; and using performance data to drive corrective action.
- Experience establishing standard work, operator training, skills qualification, and disciplined daily management routines.
- Working knowledge of process control, root-cause analysis, corrective action, and continuous improvement methods. Ability to interpret operating data and support process capability and validation activities.
- Understanding of manufacturing safety and environmental requirements in hot metal-forming operations including the operating risks associated with molten metal, equipment, and material handling.
- Ability to work in Bellevue, Ohio, for the first 18 months and relocate to a permanent position in Chicago, Illinois, afterward.
- Strong communication, organizational, analytical, and problem-solving skills. Ability to prioritize, delegate, and coordinate work across technical and support functions.
- Proficiency with Microsoft Office and manufacturing scheduling, reporting, or maintenance management systems.
PREFFERED QUALIFICATIONS
- Experience starting up or expanding a casting facility, pilot operation, or technology development center, including equipment commissioning and new program launches.
- Experience managing HPDC aluminum or magnesium casting foundries.
- Familiarity with ISO 9001, IATF 16949, control plans, PPAP, and customer-specific quality requirements relevant to assigned programs.
- Ability to interpret casting simulation results and contribute to tooling, gating, venting, and process reviews. Direct experience with MAGMA, FLOW-3D, die design, or robot programming is an advantage.
- Formal training in manufacturing, engineering, operations management, or a related field, or equivalent relevant experience.
The above statements describe the general nature and level of work performed by people assigned to this job. They are not intended to be an exhaustive list of responsibilities, duties, or skills. Related duties may be assigned as business needs evolve.
LOCATION AND WORK SCHEDULE
The first 18 months of employment will be based in Bellevue, Ohio, to support equipment installation, commissioning, and manufacturing startup. After this assignment, the position will be permanently based in Chicago, Illinois. Initial Location: Bellevue, Ohio, for the first 18 months The first 18 months of employment will be based in Bellevue, Ohio, to support equipment installation, commissioning, and manufacturing startup. After this assignment, the position will be permanently based in Chicago, Illinois. Permanent Location: Chicago, Illinois, following the initial 18-month assignment Travel: Up to 50%, including domestic and international project sites, as required
WORK ENVIRONMENT
The work environment and physical demands below are representative of those encountered while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform those functions.
- Primarily based at the Advanced Casting Technology Development Center, with regular and substantial presence on the production floor to lead teams, review conditions, and support trials and production.
- Work includes standing and walking in operating areas and sitting for planning, meetings, documentation, and reporting. Production areas may involve heat, humidity, noise, molten metal operations, and moving mechanical equipment; required protective equipment and safety procedures apply.
- Occasional travel to manufacturing sites, suppliers, and industry events may be required. Startup activities, trials, production schedules, and operating issues may require extended hours or support across shifts.
PEOPLE MATTER
PSW Group is dedicated to an open, inclusive, and trusting culture where every employee feels valued and respected. We treat employees fairly and with dignity, regardless of position or background. We recognize the contribution of a diverse employee community and are committed to a welcoming environment for all. Our open-door policy encourages employees to share their thoughts, concerns, and suggestions with management. We encourage employees to speak up at all levels, listen actively, and provide honest, responsible feedback. The safety and well-being of our employees are of utmost importance. Through training, safety procedures, and attention to operating conditions, we work to provide a safe workplace where employees can work with confidence and peace of mind. At PSW Group, we believe our people are our greatest asset, and we are dedicated to creating a workplace where they can thrive and grow.
COMP & BENEFITS
We are committed to providing a comprehensive benefits package that supports employee health, work-life balance, and financial security. Our benefits package includes a competitive salary, discretionary bonus, a 401(k) plan with a company match, medical, dental, vision, life, disability, and other group and individual coverage options.
OUR VISION
Committed to providing the highest quality raw materials.
OUR MISSION
To support our customers in building their products and be their trusted partner in innovation and success by providing superior and sustainable lightweight metal solutions.
ABOUT PSW GROUP
PSW Group is a leading recycler and producer of nonferrous lightweight metals, specializing in magnesium and aluminum. We supply a broad range of products, including secondary magnesium alloys, primary and secondary aluminum alloys, and tolling and chip recycling services. Our international production facilities in North America, Europe, and Asia provide a cross-continental supply network. We invest in technologies and processes to reduce our carbon footprint while maintaining product quality. PSW Group is committed to providing high-quality raw materials to help customers build their products and realize innovative ideas. Our products serve the automotive, aerospace, communications, construction, and electronics industries. We work to meet and exceed customer needs through quality, environmental standards, and sustainable lightweight solutions. For more information, visit www.pswgrp.com. PSW Group pursues innovation and excellence. Guided by our core values, we seek to create value for customers and advance standards in magnesium recycling. PSW Group is an equal opportunity employer committed to workplace diversity. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, age, gender identity, protected veteran status, disability, or any other protected status or non-job characteristic under applicable law.
BENEFITS
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Life insurance
- Paid time off
- Vision insurance