Capacity Expansion Manager

Summary

The Capacity Expansion Manager will be responsible for leading the planning, development, and execution of capacity expansion activities required to support major Power Gen project delivery. This role will work closely with Manufacturing, Facilities, Materials, Engineering, Procurement, Quality, Testing, Paint, Safety, Continuous Improvement, and Project Leadership to ensure the business has the operating capacity required to meet projected demands.

The term “capacity” includes more than building space or shop layout. It includes the full operating capacity required, including workforce planning, labor availability, parking, traffic flow, employee access, material handling, utilities, test capacity, painting, warehouse space, staging, preservation, shipping lanes, support areas, supervision coverage, tooling, equipment, and daily shop rhythms.

The role will be responsible for developing the capacity expansion plan, coordinating readiness of new or modified shop areas, supporting test-bay development, establishing material and equipment flow, coordinating workforce and support-area needs, and ensuring the facility can support safe, efficient, repeatable execution.

A key expectation of this role is to build continuous improvement into the capacity model from the beginning. The Capacity Expansion Manager should not only help create the physical space, but also help establish the operating rhythms, visual management, standard work, material-flow discipline, problem-solving routines, and performance metrics needed to improve safety, quality, delivery, cost, and team effectiveness over time.

This person will help develop staffing plans, aligned with the finalized execution processes, as well as work with Human Resources and Manufacturing Leadership on staffing and training plans through move-in and ramp-up periods.

Once capacity targets are met and new work areas are fully operational, this role will transition into a key leadership role focused on continuous improvement of the facility, production leadership, or other regional strategic efforts.

Principle Responsibilities and Duties

Facility Expansion & Readiness

• Lead facility expansion and readiness activities to support Power Generation production demand.
• Partner with Manufacturing and Facilities leadership to develop shop layouts, assembly flow, workforce plans, material movement, staging, testing, preservation, parking, traffic flow, and shipping access.
• Coordinate facility readiness, including utilities, equipment installation, tooling, test bays, workforce ramp-up, and support infrastructure.
• Ensure expansion plans support production capacity, safety, quality, and delivery commitments while identifying and resolving capacity constraints.

Manufacturing Flow & Continuous Improvement

• Develop efficient assembly flow, work centers, staging areas, inspection points, test areas, and finished goods storage.
• Collaborate with Manufacturing, Engineering, Materials, and Quality to improve workflow, reduce bottlenecks, rework, material shortages, and non-value-added activities.
• Support standard work, visual management, production metrics, and daily operating rhythms.
• Drive continuous improvement through root cause analysis, production data, lessons learned, and employee feedback to improve safety, quality, and throughput.

Workforce & Operational Planning

• Coordinate with Manufacturing, Facilities, HR, HSE, and Project Leadership to plan workforce requirements, labor ramp-up, supervision, onboarding, training space, parking, employee access, and operational support.
• Identify workforce and facility readiness risks and ensure solutions are implemented before production demand increases.
• Align workforce planning with production schedules, facility layout, and operational requirements.

Testing, Staging & Preservation

• Coordinate readiness of test bays, paint expansion, utilities, staging areas, preservation processes, and shipping flow.
• Define material staging, work-in-process, finished goods storage, and preservation requirements.
• Improve testing, staging, and preservation processes to reduce delays, handling, rework, and quality issues.

Cross-Functional Leadership

• Partner with Project Management, Manufacturing, Engineering, Materials, Procurement, Quality, Testing, HSE, Facilities, and Operations to align facility readiness with project schedules.
• Support decisions related to equipment, tooling, staffing, infrastructure, and shop layout while communicating readiness, risks, constraints, and improvement opportunities to leadership.

Safety & Quality

• Incorporate safety, quality, material flow, traffic management, inspection points, NCR containment, and operational readiness into facility design and production planning.
• Conduct readiness reviews before new areas or processes are released and promote a clean, organized work environment focused on continuous improvement.

Qualifications

Education

• Bachelor’s degree from a four-year college or university preferred.
• Degree in engineering, construction management, operations, manufacturing, industrial technology, or a related field preferred.
• Equivalent facility, manufacturing, or operations leadership experience may be considered.
  
  

Previous Assignments

• Experience in facility expansion, shop operations, manufacturing, fabrication, assembly, construction, or industrial operations.
• Experience leading or supporting facility layout, production flow, material movement, shop readiness, manufacturing ramp-up, or continuous improvement initiatives.
• Experience working with cross-functional teams, including Manufacturing, Facilities, Materials, Engineering, Quality, Safety, and Project Management.
• Experience with heavy industrial equipment, modular equipment, oil and gas, power generation, or engineered systems preferred.
• Experience leading shop teams or production operations preferred.
• Experience managing contractors, vendors, equipment installation, utilities, or facility-readiness activities preferred.
• Experience with lean manufacturing, visual management, standard work, root-cause analysis, or structured problem solving preferred.
  
  

Required Skills / Tools

• Strong leadership skills with the ability to create structure, ownership, and accountability.
• Strong understanding of shop flow, material movement, staging, production readiness, safety, quality, and operational execution.
• Ability to work effectively in a matrix organization across facilities, manufacturing, materials, engineering, quality, safety, project teams, and continuous improvement resources.
• Strong planning, coordination, and problem-solving skills.
• Ability to identify waste, bottlenecks, recurring constraints, and improvement opportunities.
• Ability to manage multiple priorities in a fast-paced environment.
• Strong communication skills with the ability to escalate risks and drive decisions.
• Proactively identifies constraints, removes barriers, and implements practical improvements.
• Working knowledge of Microsoft Office required.
• Experience with Microsoft Project, SharePoint, Teams, layout tools, project tracking tools, or continuous improvement tools preferred. 

*Applicants must be legally authorized to work in the United States. Currently, our organization is unable to consider candidates who require visa sponsorship or the transfer of an existing visa to obtain or maintain work authorization in the United States

Physical Requirements

• Fast-paced general office environment. Many tasks have high degrees of time sensitivity.
• May be exposed to confidential information.
• May be required to work non-standard hours including evenings and weekends
• May be required to travel up to 10%