You will lead the setup, commissioning, and ongoing management of a new timber doorset and finishing production facility, covering machining, assembly, pre‑hung doorsets, and finishing operations. This role combines hands‑on production leadership, project management, and embedding of continuous improvement through LEAN methodology and tools, supporting delivery in full, to budget, and on time to ensure the operation is capable of achieving required output, quality, and compliance standards, e.g., fire doorsets.
You will be responsible for building the production workflow from the ground up—specifying equipment and facility requirements, establishing processes, recruiting and training staff, and driving operational excellence once the facility is live.
Key Responsibilities
Facility Setup & Project Management
* Act as the SME for the end‑to‑end setup of a new timber doorset production facility, from layout design to commissioning.
* Support Procurement and assist with suppliers to specify, procure, and install machinery (CNC, beam saw, wide belt sander, spray booth, Schubox/drying systems, extraction, compressors, assembly benches, and packaging equipment).
* Develop factory layout, material flow, and lean production processes to maximise efficiency and minimise waste.
* Oversee installation, testing, and optimisation of all equipment and production lines.
* Work with SHEQ Manager and HO Operations to ensure compliance with HSE, fire safety, ATEX, PUWER, and environmental requirements.
Production Management
* Manage daily operations across machining, assembly, finishing, and dispatch.
* Plan and schedule production to meet customer lead times and quality standards.
* Implement and maintain SOPs, quality checks, and process controls for fire doors, acoustic doors, and standard timber doorsets.
* Monitor KPIs, including throughput, yield, downtime, labour efficiency, and OTIF performance.
* Lead root‑cause analysis and continuous improvement initiatives (Lean, 5S, Kaizen).
* Ensure correct handling, curing, and finishing processes for prefinished doors, including IR drying/Schubox systems.
Team Leadership
* Recruit, train, and develop a high‑performing production team.
* Provide daily supervision, ongoing coaching, formalised one‑to‑ones and performance management.
* Foster a culture of safety, accountability, and continuous improvement.
* Ensure cross‑training to build a flexible, multi‑skilled workforce.
Quality, Compliance & Technical Oversight
* Ensure all doorsets meet relevant standards (e.g., PAS 24, Secured by Design, fire certification, and acoustic ratings).
* Work with technical and compliance teams to maintain certification and traceability.
* Oversee finishing quality, colour consistency, and coating performance.
* Manage non‑conformance, rework, and customer returns processes.
Supply Chain & Materials Management
* Work with procurement to source timber, cores, hardware, coatings, and consumables.
* Implement stock control systems for raw materials, WIP, and finished goods.
* Optimise material usage and reduce waste.
Skills & Experience Required
Essential
* Proven experience managing production in a timber doorset, joinery, or woodworking manufacturing environment.
* Demonstrated success in setting up a new production facility, including equipment specification, layout design, and commissioning.
* Hands‑on understanding of CNC machining, CNC programming, door panel processing, sanding, finishing, and assembly processes.
* Experience with IR drying/Schubox or similar low‑temperature curing systems.
* Strong leadership skills with experience supervising production teams.
* Excellent understanding of SHEQ, PUWER, ATEX, and manufacturing compliance.
* Ability to read technical drawings and interpret specifications.
* Strong problem‑solving and continuous improvement mindset.
Desirable
* Experience with fire door manufacturing and certification processes.
* Knowledge of lean manufacturing, 5S, and process optimisation.
* Experience utilising ERP/MRP systems in a manufacturing environment.
* IOSH/NEBOSH qualification.
What Success Looks Like
* A fully operational, efficient, safe, and compliant production facility delivered on time.
* Stable, predictable production output with high quality and low rework.
* A trained, motivated team working to clear processes and standards.
* Continuous improvement embedded into daily operations.
* Strong collaboration across technical, commercial, and operational teams.
What We Offer
* Opportunity to shape and lead governance processes in a fast‑growing business.
* A supportive environment where your expertise will make a real impact.
* A culture that values your professional growth and personal wellbeing.
* Generous Holiday Allowance
Enjoy 22 days of annual leave, plus bank holidays, with the flexibility to tailor your time off:
o Buy up to 3 extra days of holiday
o Or sell back up to 2 days to suit your needs
* We believe in a healthy work‑life balance that works for you.
* Length of Service holiday awards: 1 extra day for every 3 years service.
* Death in Service benefit (3x annual salary).
* Salary sacrifice pension scheme with employer contributions of 3% in line with current statutory requirements.
* Salary sacrifice Cycle‑to‑work scheme.
* Staff discounts on the Leader product range.
* Subsidised gym membership.
* Your Wellbeing Matters
o Access to Able Futures, a confidential government‑backed service providing practical support for mental wellbeing at work.
o Employee Assistance Programme (EAP) – 24/7 access to professional wellbeing advice, counselling, and guidance to help you thrive inside and outside of work.
* Employee Referral Bonus
* Salary £40000 - £44000 Dependent on Experience
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