Program Development Manager Jobs in Madisonville, KY

General Summary: Leads the planning, coordination, execution, and successful launch of all new programs and major capital projects for the facility. Serves as the primary liaison between Toyota Boshoku Western Kentucky, TBA Production Engineering (PE), suppliers, contractors, and internal departments to ensure alignment of program objectives, timelines, budgets, and customer requirements. Responsible for managing and reporting all PEFF Plant activities, equipment procurement coordination, equipment reception and installation planning, launch readiness, risk management, budget tracking, and executive reporting. Drives cross-functional collaboration and accountability across Manufacturing, Production Engineering, Maintenance, Quality, Safety, Production Control, and Administration to ensure successful implementation of new equipment, processes, and customer programs. Identifies program risks, develops countermeasures, and ensures all projects are executed safely, on schedule, within budget, and in support of the plant's strategic objectives.
Essential Job Functions:
A. Lead and coordinate all phases of new program launches, capital projects, equipment implementation, and production readiness activities to ensure successful execution of customer requirements, project timelines, quality standards, and business objectives.
1. Collect information and research data related to manufacturing feasibility, safety requirements, quality standards, equipment requirements, and operational readiness to support successful program implementation.
2. Coordinate design reviews and provide input regarding manufacturability, quality, cost, timing, and process capability requirements.
3. Analyze and provide input regarding quality of raw materials, purchased parts, equipment specifications, and other items required to support production requirements.
4. Support development and review of manufacturing processes, line layouts, facility requirements, and equipment installation plans to achieve operational, quality, and cost objectives.
5. Analyze processes for improvement opportunities, failure modes, process stability, capability, and risk mitigation.
6. Develop, maintain, and track program schedules, milestones, deliverables, launch readiness activities, and open issues through project completion.
7. Coordinate equipment procurement, reception, installation, commissioning, validation, and startup activities for new and existing programs.
8. Manage PEFF activities associated with new programs, capital expenditures, facility modifications, and equipment investments, including budget tracking and project reporting.
9. Lead cross-functional project meetings and coordinate activities among Manufacturing, Production Engineering, Maintenance, Quality, Safety, Production Control, Administration, suppliers, contractors, and other stakeholders.
B. Serve as the primary liaison between the plant, TBA Production Engineering (PE), customers, suppliers, contractors, and external stakeholders regarding program implementation, equipment integration, manufacturing capability, quality requirements, and technical support activities.
C. Manage and control Engineering Change Requests (ECRs), Engineering Change Instructions (ECIs), customer-driven changes, and other program modifications to ensure timely implementation and communication across affected departments.
D. Create, maintain, and manage project schedules to meet customer implementation dates, project milestones, equipment installation requirements, and launch timing objectives while tracking open issues through resolution.
E. Initiate, prepare, present, and implement plans for program execution, process improvements, risk mitigation, launch readiness, and operational support activities. Train and support team members as required.
F. Ensure completion of all required testing, validation, commissioning, and launch readiness activities for new products, equipment, and manufacturing processes.
G. Create, review, and maintain CAD data, engineering documentation, project records, and technical information as required.
H. Support manufacturing operations in achieving required Key Performance Indicators (KPIs) through effective launch management, project coordination, process improvements, and operational support.
I. Prepare and complete all required daily, weekly, monthly, and project reporting activities in accordance with TBA and TBWK requirements, including executive-level project status updates.
J. Coordinate project activities, resources, contractors, suppliers, and plant team members to ensure successful completion of program objectives, equipment installations, capital projects, and customer requirements.
K. Identify project risks, develop countermeasures, escalate barriers, and drive issue resolution to ensure projects are executed safely, on schedule, within budget, and in compliance with customer and company requirements.
L. Provide project leadership through cross-functional collaboration, influence, and accountability to achieve program objectives without direct supervisory authority.

• Minimum Qualifications/Requirements:

Education:

• Bachelor's degree in Business, Manufacturing, or related field required, or an equivalent combination of education and relevant experience.

Experience:

• Greater than eight (8) years of relevant experience required.
• Greater than four (4) years of professional management experience required.

Personal/Technical Skills:

• Strong organization and planning skills.
• Ability to communicate and work well with all levels of the organization.
• Ability to multitask, manages diversity, and facilitates problem solving and resolution.
• Ability to work in a team environment.
• Effective time management skills.
• Excellent critical thinking skills required.
• Good assertiveness and negotiation skills.
• Ability to understand inspection standards.
• Hands-on, self-starter with a strong work ethic.
• Ability to perform responsibilities with minimal supervision.
• Ability to work in a fast-paced, multicultural work environment.
• Ability to maintain records and files and prepare recaps and reports.
• Ability to maintain on call flexibility to control abnormal conditions
• Ability to create excellent working relationships with internal and external customers.
• Must be able to work a fixed or rotating shift schedule, including daily or weekend overtime.
• Ability to multitask, manage diversity, and facilitate effective problem solving and resolution
• Auto CAD experience is desirable.

Language Skills:

• Strong verbal and written communication skills in English.

Computer/Software:

• Solid working knowledge and experience with Microsoft Office and other computer-based applications (e.g., MS Word, MS Excel, MS PowerPoint, Lotus Notes/Outlook, Internet, etc.).

1. Work Environment/Conditions:

Office: Open Office Environment, moderate noise level.
Plant: Standard automotive plant environment with moderate noise level. PPE (Personal Protective Equipment) such as safety glasses, steel toe shoes, hearing protection, etc. may be required in engineering, manufacturing, or industrial areas. Personal attire standards may apply.
Travel: 0-5%

1. Physical Demands:

Ability to sit and work on a computer for extensive periods of time is required. While performing the duties of this job, the team member is required to talk, see, and hear. The team member must be capable of walking, sitting, and standing for extended periods of time. May be occasionally required to lift up to 30 pounds.
Disclaimer: This job description is intended to identify the general nature and level of work performed by team members within this classification, as well as certain essential job functions. It is not intended, and should not be interpreted, as a comprehensive inventory of all duties, responsibilities, and qualifications required of team members assigned to this job. To qualify for this job, however, a team member must be able to perform its essential functions with or without reasonable accommodation. Under no circumstances may this job description be construed as altering the at-will nature of the employment relationship between TBA and any team member.
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