Reports to: COO
Direct Reports: Line Leaders (Cutting; Sewing; Machine Operations)
Compensation: $55,000- $80,000
Role summary
Shaw Concepts is scaling a cut-and-sew manufacturing operation for tactical soft goods and armor components. We are hiring a Production Systems Manager for a cut and sew operation to own daily production across cutting, sewing, and machine operations while building a simple, repeatable operating system that increases throughput without simply adding more people doing the same work. This role will lead the transition from a demand-led, high-mix / low-volume workflow into a production-led, cell-based manufacturing model capable of higher volume with predictable output, quality, and material control.
This is not a “scheduler/planner-only” role. You will be on the floor, in the details:
- Labor allocation and daily execution
- Bottleneck identification and removal
- Standard work and line balancing
- Training and onboarding systems
- Material flow discipline and usage control
You will develop line leaders, onboard and train new hires as headcount scales from ~10 to ~20 within 12 months and possibly prepare the operation to grow from one shift to two shifts.
Key outcomes (what success looks like)
- Throughput increases measurably and consistently (output per person, output vs plan), with daily visibility and fast issue resolution.
- Labor efficiency improves (standard hours vs actual hours) with clear standards, balanced work, and reduced rework/interruptions.
- Material consumption is controlled and optimized (usage accuracy, yield, scrap reduction), with disciplined kitting and flow.
- Cell manufacturing is implemented for repeatable product families (clear work content, staffing model, cross-training coverage).
- A repeatable daily/weekly manufacturing operating system exists (cadence, KPIs, standard work audits) and is used consistently.
- New hires ramp faster and line leaders run the floor effectively with accountability, coaching, and consistent standards.
Core responsibilities
Own daily production execution (Cutting, Sewing, Machine Operations)
- Run daily production planning and floor execution: staffing, priorities, bottleneck management, and plan vs actual.
- Manage WIP flow and handoffs across cutting → sewing → machine operations to maintain pace and reduce aging.
- Lead a daily operating rhythm (tier meeting, constraints review, staffing adjustments, issue escalation and closure).
- Maintain stable output while balancing high-mix demand today and the shift toward more repeatable production tomorrow.
Build and run a simple manufacturing operating system (throughput-focused)
- Define the few KPIs that matter and make them visible daily (throughput per person, labor efficiency, material usage, schedule adherence).
- Implement standard work and work measurement appropriate for a small team (standard hours, targets, clear definitions of “done”).
- Introduce WIP limits, visual management, and basic problem-solving routines so issues are surfaced and solved fast.
- Create a weekly cadence with line leaders: KPI review, constraint plan, staffing/training plan, and improvement priorities.
Lead the transition to cell manufacturing (general sewing → scalable cells)
- Identify product families appropriate for cells and design the cell flow (operations sequence, staffing model, takt/targets).
- Balance work content, reduce handoffs, and improve flow using lean methods (line balancing, waste reduction, changeover reduction).
- Build cross-training plans and a skills matrix to support flexible staffing inside cells and reduce single points of failure.
- Launch, stabilize, and scale cells while maintaining performance in legacy workflows during the transition.
Scale the team and lead change management
- Hire, onboard, and train operators as production scales from ~10 to ~20+ within 12 months.
- Develop line leaders to run consistent standards, execute the daily rhythm, and coach performance on the floor.
- Lead frequent process and workflow changes using a simple approach: pilot → train → implement → audit → improve.
- Drive adoption and accountability so changes “stick” without creating confusion, thrash, or morale loss.
Materials discipline and Katana MFG ERP execution
- Ensure production is accurately executed and reported in Katana (work orders, routings, inventory consumption, production outputs).
- Drive disciplined kitting and point-of-use material flow to reduce downtime and improve usage accuracy.
- Improve yield and reduce scrap/rework tied to material handling, cutting accuracy, and process variation.
- Partner with planning/purchasing to prevent shortages, manage substitutions correctly, and protect schedule stability.
Requirements
- 10+ years of leadership experience in cut-and-sew manufacturing (production supervision/management).
- Demonstrated lean manufacturing experience in a sewn goods environment (standard work, line balancing, flow, cells).
- Proven ability to lead through change in a scaling operation (clear communication, adoption, accountability).
- Track record of building teams and developing leaders (training, onboarding, line leader management).
- Strong command of throughput metrics: labor efficiency (standard vs actual), output vs plan, WIP control, schedule adherence.
- Comfortable working in an ERP-driven operation; Katana MFG ERP experience is a plus.
Preferred
- Experience moving operations from demand-led to production-led planning and execution.
- Experience preparing and launching a second shift (staffing model, training pipeline, handoffs, KPI cadence).
