- US Plant Manager & Operations Leader
- Reporting: Chief Operating Officer
- Location: Massachusetts
BSG has commenced an executive search for a US Plant Manager & Operations Leader for our client, an innovative manufacturer and distributor focused on developing cutting-edge photo sensor technologies. The US Plant Manager & Operations Leader is an experienced and technically adept leader who will lead the establishment and operation of a new night vision manufacturing facility.
Opportunity Overview
US Plant Manager & Operations Leader
THE COMPANY
Our client is an innovative manufacturer and distributor focused on developing cutting-edge photo sensor technologies for various applications ranging from optics for night vision to space exploration and high-energy physics experiments in labs. Since 1937, our client has innovated for demanding customers with a need for mission-critical components.
Our client has four manufacturing locations that are ISO certified. With their headquarters in France, their other facilities are located in the Netherlands, and United States of America (Massachusetts and Pennsylvania). These facilities are supported by Engineering, Research and Development, Program Management Departments, and Quality Management Systems.
THE POSITION
Reporting to the Chief Operating Officer, the US Plant Manager & Operations Leader is an experienced and technically adept leader who will lead the establishment and operation of a new night vision manufacturing facility. This greenfield facility will serve as a critical extension of the company’s European operations in France and the Netherlands, supporting high-precision manufacturing processes for night vision intensifier tubes. The US Plant Manager & Operations Leader will oversee facility construction, operational ramp-up, staffing, budget management, and long-term efficiency optimization to achieve a production target of 20,000 units per year by the end of Year 1.
Essential Duties and Responsibilities
Facility Build-Out and Capital Projects:
- Oversee plant design, construction, permitting, and budget management to ensure timely and cost-effective execution.
- Manage the internal build-out of the facility, ensuring all milestones are met on time and within budget.
- Supervise landlord-paid improvements, including permitting and construction.
- Define and implement operational workflows, shift structures, and employee cadences.
Operations and Manufacturing Launch:
- Hire and onboard a 70-person manufacturing and operations team, including 45 operators and 25 supporting roles (engineering, QA, maintenance, etc.).
- Establish a multi-shift (24/7) production operation.
- Partner with engineering to set up production lines and deliver the first qualification “live run” by July 1, 2026.
- Ensure the first commercially viable part is produced by December 31, 2026.
- Implement a barcode labor tracking system to accurately determine the real cost per SKU.
- Optimize manufacturing efficiency to ramp up to 20,000 units per year in Year 1.
Process Optimization and Continuous Improvement:
- Apply lean manufacturing principles and OEE (Overall Equipment Effectiveness) methodologies to maximize equipment utilization.
- Drive efficiency improvements through automation and process innovation.
- Implement SAGE ERP/shop floor system upgrades for manufacturing & supply chain.
Cross-Site and International Coordination:
- Establish strong collaboration with the European night vision manufacturing teams in France and the Netherlands.
- Align best practices, technology, and process improvements across all sites.
- Facilitate training programs and travel for U.S. employees to European manufacturing sites.
Qualifications and Experience:
- 10 years’ experience in manufacturing industries with high-quality and cleanliness standards (e.g., semiconductors, medical devices, aerospace/defense).
- 5 years’ experience with plant management and operations.
- Engineering degree required (Mechanical, Electrical, Industrial, or related fields).
- Proven plant leadership experience in a capital-intensive, high-precision manufacturing environment.
- Strong background in lean manufacturing, OEE, and continuous improvement methodologies.
- Familiarity with optics, mechanics, and vacuum technology is a plus.
- Ability to work in a global, multi-site environment, communicating with teams across different time zones and cultures.
- Strong interpersonal and management skills, capable of balancing technical expertise with people leadership.
- Experience with SAGE.
Who We’re Looking For:
- A hands-on leader who is comfortable rolling up their sleeves.
- A problem solver who thrives in an entrepreneurial, fast-paced environment.
- Someone who can balance strategy with execution.
- A servant leader who listens, collaborates, and empowers their team.
- A leader with international experience, who understands cultural and operational differences.
Performance Metrics:
- Facility build-out completed on time and within budget.
- Manufacturing line operational by July 1, 2026, with first commercial product by December 31, 2026.
- Ramp-up to 20,000 units/year and $50M revenue in Year 1.
- Implementation of cost-tracking and efficiency optimization systems.
- Successful integration with European manufacturing partners.
This is a career-defining opportunity to establish a world-class manufacturing operation in a cutting-edge industry.
Ideal Candidate Profile
The ideal candidate has a strong engineering background, expertise in lean manufacturing, and a deep understanding of high-quality, capital-intensive production environments such as semiconductors, medical devices, or aerospace/defense. A key aspect of this role is coordinating globally across time zones, ensuring seamless integration with European partners. A summary of key competencies required to be successful include the following:
FUNCTIONAL EXPERIENCE
- Experienced operations/manufacturing leadership with previous successful endeavors in high-tech manufacturing, imaging technology, or electro-optical manufacturing.
- Experienced with greenfield or plant start-up operations including capital projects.
- Experienced leader and manager of manufacturing operations, multi-functional departments, multi-line, multi-shift manufacturing operations.
- Strategic project management – demonstrated experience creating and driving efficiencies and growth initiatives.
INDUSTRY
- Electro-optical, imaging technology, high-tech manufacturing with high-quality and cleanliness standards (e.g., semiconductors, medical devices, aerospace/defense).
- Understanding of TWM, Lean/Six Sigma manufacturing processes.
- Understanding of Robotics Automation.
- Experienced with ERP Implementation, Shopfloor Data Collection, and Time Motion Studies.
CORPORATE STAGE
- Must have Private company manufacturing experience in career history.
- Single plant is manufacturing $25M/year (revenue from their products).
- Managed a team of 20+.
- Total plant size 50-200 employees.
- $25M - $75M company revenue experience.
MANAGEMENT & LEADERSHIP EXPERIENCE
- Hire and onboard manufacturing and operations team. Develop the team across capabilities by coaching, identifying areas for growth, celebrating successes, managing promotion process, keeping an open dialogue with the team, identifying training opportunities.
- Establish and grow relationships across capabilities and with international corporate manufacturing and operations teams.
- Demonstrate mature leadership and empathy in difficult team situations – a player/coach who leads by example.
- Demonstrate experience managing timelines and budgets.
- 10 years’ experience in manufacturing plant environment, high-tech, robotics automation preferred.
- 5 years’ experience with plant operations management.
MARKETS & CUSTOMERS
- Analytical instrumentation
- Defense
- Medical
- Nuclear Instrumentation
- Security & Surveillance
COMPENSATION
Compensation is competitive with the position’s requirements. In a performance-based environment, this will include base salary, bonus structure based on corporate qualitative and quantitative strategic KPI’s and company performance.
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