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Director of Operational Excellence

Frito Division - Qual Pac

Position Summary

The Director of Operational Excellence is responsible for designing, deploying, and sustaining the operational excellence and productivity framework across Qual Pac's Frito Division network of five manufacturing facilities.

This role serves as the division's operational performance leader, driving continuous improvement initiatives, productivity enhancement programs, labor and facility optimization, operational standardization, and workforce capability development. The Director works closely with Site Leaders, Engineering, Finance, and Site Leadership to identify and implement sustainable improvements that strengthen operational performance, protect margins, and support long-term growth.

A key component of this role is regular travel to manufacturing sites to conduct operational assessments, facilitate performance improvement initiatives, develop and implement best practices, and deliver leadership and technical training programs for key operational positions.

The Director does not directly manage day-to-day plant operations but serves as a strategic partner and subject matter expert responsible for enabling operational excellence across the network.

Key Objectives

• Achieve contractual 2% annual productivity improvement commitments.
• Identify and support an additional 1-3% annual internal margin improvement opportunities.
• Develop and standardize best practices across all facilities.
• Support automation initiatives through operational redesign and capability development.
• Improve labor efficiency, material flow, facility utilization, and operational effectiveness.
• Build organizational capability through training, coaching, and leadership development programs.

Reporting Structure

Reports To: Division Director, Frito Operations

Dotted Line: Vice President, Qual Pac

Key Internal Partnerships:

• Site Leaders
• Plant Management Teams
• Engineering
• Finance and Controller
• Human Resources

Direct Reports: None

Core Responsibilities

Operational Excellence Leadership

• Develop and deploy the division-wide Operational Excellence strategy.
• Lead continuous improvement initiatives focused on safety, quality, productivity, service, and cost performance.
• Establish operational standards and performance systems across all manufacturing locations.
• Drive adoption of Lean Manufacturing, 5S, and continuous improvement methodologies.
• Facilitate structured problem-solving processes and root-cause analysis activities.

Productivity & Performance Improvement

• Partner with site leadership teams to identify and execute annual productivity initiatives.
• Build and maintain a prioritized improvement pipeline supporting contractual productivity commitments and margin enhancement goals.
• Establish standardized productivity tracking systems and reporting tools.
• Lead monthly productivity reviews with site and divisional leadership.
• Partner with Finance to validate savings and ensure accountability for results.

Site Performance Assessments

• Conduct routine visits to all manufacturing facilities.
• Evaluate operational performance, labor utilization, efficiency metrics, and workflow effectiveness.
• Identify performance gaps and develop corrective action plans.
• Coach site leadership teams on improvement opportunities and implementation strategies.
• Facilitate cross-site sharing of successful practices and proven solutions.

Best Practice Development & Standardization

• Identify, document, and deploy best practices across the manufacturing network.
• Create standardized operating procedures, workflows, and performance management systems.
• Support consistent execution of planning, scheduling, inventory control, and operational processes.
• Ensure successful implementation and sustainability of standardized practices.

Leadership Development & Training

• Design and deliver operational excellence training programs for key manufacturing leadership positions.
• Develop training curricula focused on continuous improvement, labor management, productivity, problem solving, and operational leadership.
• Coach supervisors, managers, and site leaders on performance management and operational best practices.
• Partner with HR and Operations Leadership to establish career development pathways and capability-building initiatives.

Automation & Productivity Optimization

• Evaluate operational impact and labor implications of automation investments.
• Identify secondary productivity opportunities resulting from automation implementation.
• Develop strategies to offset productivity givebacks and maximize return on investment.
• Support operational transitions associated with new technology deployment.

Labor & Organizational Effectiveness

• Develop standardized labor models for production, warehousing, and support functions.
• Benchmark labor utilization across facilities and identify optimization opportunities.
• Evaluate staffing structures, shift patterns, overtime utilization, and workforce deployment.
• Recommend organizational and operational changes that improve efficiency and effectiveness.

Material Flow & Facility Optimization

• Assess inbound and outbound logistics processes, dock operations, and material flow systems.
• Identify bottlenecks impacting throughput, service levels, and labor productivity.
• Develop standardized staffing and workflow models.
• Support facility throughput and capacity optimization projects.
• Recommend process improvements that enhance operational flow and reduce waste.

Performance Analytics & Reporting

• Monitor key performance indicators and operational trends.
• Analyze production performance, downtime, labor productivity, and facility utilization.
• Develop dashboards and executive reporting tools.
• Prepare and present operational performance reviews to divisional and executive leadership.
• Support strategic planning through data-driven analysis and recommendations.

Qualifications

Education

• Bachelor's degree in Engineering, Operations Management, Supply Chain, Business, or related field required.
• Master's degree preferred.

Experience

• 8+ years of progressive manufacturing, operations, operational excellence, or continuous improvement experience.
• Experience leading multi-site improvement initiatives.
• Strong background in productivity improvement, labor optimization, and operational transformation.
• Experience within food manufacturing, consumer packaged goods, or high-volume manufacturing environments preferred.

Technical Skills

• Lean Manufacturing
• Six Sigma methodologies
• Root Cause Analysis
• Labor Modeling and Productivity Analysis
• Financial Modeling and ROI Analysis
• Continuous Improvement Systems
• Operational Performance Management
• Microsoft Excel, Power BI, and reporting tools

Travel Requirements

• Regular travel to manufacturing facilities is required. (up to 50%)
• Expected travel of approximately 30-50%, including routine site visits, operational assessments, training facilitation, project implementation, and leadership development activities.

Professional Development Expectations

Within 12-24 months, the Director will:

• Establish a sustainable Operational Excellence program across all facilities.
• Implement a division-wide best practice and knowledge-sharing framework.
• Develop and deploy training programs for key operational leadership positions.
• Strengthen organizational capability in Lean Manufacturing and continuous improvement principles.
• Enhance financial and operational decision-making through advanced analytics and performance modeling.
• Serve as a recognized operational excellence leader across the Qual Pac network.