Plant Director

Company: A123 Systems
Location: Novi
Posted on: May 3, 2025

Job Description:

A123 Systems, LLC in Novi, Michigan is hiring a Plant DirectorThe Plant Director is responsible for overseeing and managing all aspects of plant daily operations, including production, safety, maintenance, staffing, and continuous improvement initiatives for lithium ion battery module, pack and container plant. This role involves strategic leadership, ensuring efficient manufacturing processes while adhering to strict safety, environmental, and regulatory standards. The director will collaborate with cross-functional teams, such as engineering, supply chain, quality and R&D, to achieve production goals, enhance performance, and drive innovation in battery manufacturing.Specific responsibilities include:

• Develop and implement operational strategies to achieve organizational goals and objectives
• Lead day-to-day operations of the lithium-ion battery production line, ensuring all production targets, timelines, and quality standards are met.
• Develop and execute operational strategies to scale production capacity, improve processes, and drive operational excellence.
• Collaborate with senior leadership to align plant objectives with the overall company vision and goals.
• Manage a team for factory layouts and facility design, process flow, material flow and logistics, including the design and implementation of production lines, workstations, and equipment, and infrastructure requirements, including utilities.
• Implement and manage manufacturing processes to optimize efficiency, reduce costs, and enhance product quality.
• Develop and oversee production schedules, ensuring proper resource allocation and workforce planning
• Foster a collaborative, high-performance culture that promotes employee engagement, development, and retention.
• Identify areas for process improvement and lead initiatives to reduce inefficiencies, downtime, and operational costs.
• Monitor key performance indicators (KPIs) and track plant performance against targets
• Collaborate with the supply chain team to ensure the availability of raw materials and components needed for production and manage inventory levels, ensuring minimal downtime due to material shortages.
• Develop and manage plant budgets, ensuring cost-effective operations
• Communicate regularly with internal and external stakeholders, providing updates on production, quality, safety, and other key performance metrics.
• Oversee plant Environment, Health and Safety initiatives
• Ensure compliance with quality systems, customer expectations, and regulatory requirements
• Create and implement contingency plans to mitigate the impact of potential disruptions, ensuring that manufacturing goals can still be met in the face of unforeseen challenges
• Bachelor's degree in Engineering (Electrical, Mechanical, Industrial, or related field) required; MBA or advanced degree is a plus.
• Extensive knowledge of lithium-ion battery module/pack technology and manufacturing processes
• Proven track record of successfully leading large-scale manufacturing operations, including staff management and cross-functional collaboration
• Familiarity with lean manufacturing principles and process optimization techniques
• In-depth knowledge of manufacturing processes, quality control, and regulatory compliance
• Proven ability to lead and motivate large teams in a manufacturing setting
• Strong communication and interpersonal skills to interact with all levels of the organization
• Ability to think critically, solve complex problems, and make decisions under pressureThe must haves:
  • Minimum of +12 years of experience in a manufacturing environment, with a focus on the production of lithium-ion battery modules and packs or similar electrochemical products
  • 7+ years of experience in managing manufacturing engineering team
  • Strong experience in lithium-ion battery production or related industries, with knowledge of module/pack and BESS container manufacturing, planning, assembly, and testing processes.
  • Experience with lean manufacturing, Six Sigma, or similar process improvement methodologies. Certification in Lean Six Sigma can be beneficial.
  • Knowledge of automation (e.g., robotics, AI-driven process control, machine learning applications) to improve production efficiency
  • Strong skills in data collection, analysis, and visualization tools (e.g., SPC, Six Sigma, Minitab) for performance tracking and process optimization
  • Strong ability to analyze complex problems in battery manufacturing and implement solutions quickly, be creative, self-motivated and methodically especially when production issues ariseWhy you should work here:
    • Great annual salary dependent on experience
    • Multiple health benefit options to fit you and your family.
    • 401k with company match
    • An abundance of voluntary benefits including Dependent Care FSA, Pet Insurance, Critical Care Insurance and more!
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Keywords: A123 Systems, Sterling Heights , Plant Director, Executive , Novi, Michigan