The Senior NPI Program Launch Manager provides strategic leadership and oversight of complex, high-value tooling, manufacturing, and new product introduction (NPI) programs from concept through full-scale production within the medical injection molding division. This role ensures programs are delivered on time, within budget, and in compliance with all customer, quality, and regulatory requirements.
Acting as a key business partner, the Senior Manager drives cross-functional alignment, customer satisfaction, operational readiness, and continuous improvement across all manufacturing sites. In addition, this role mentors junior and mid-level program managers, refines NPI processes, and partners with executive leadership to establish best-in-class launch systems.
Key Responsibilities
Strategic Program Leadership
- Lead the full lifecycle of major manufacturing and NPI programs, including planning, risk management, execution, and closure.
- Define project scope, objectives, resources, and budgets to align with business strategy.
- Develop and oversee program budgets, forecasts, KPIs, and financial performance reporting.
- Track progress, manage risks, and ensure programs meet customer, cost, quality, and delivery objectives.
- Drive program governance through structured reviews, milestone management, and executive reporting.
- Oversee site-to-site program transfers, ensuring smooth relocation of tooling, processes, and documentation.
- Champion early feasibility, DFM / DFMEA reviews, technical risk mitigation, and manufacturability planning.
Cross-Functional Leadership
Direct cross-functional teams in Engineering, Tooling, Quality, Supply Chain, and Production.Resolve conflicts, remove roadblocks, and maintain alignment between operations, quality, and customer requirements.Lead make / buy decisions and manage global tooling design, build, and validation activities.Oversee prototype development, tool builds, validation, and process capability readiness.Support site readiness planning, capacity alignment, and global launch synchronization.Customer & Stakeholder Engagement
Serve as the primary point of contact for high-value customer programs.Conduct executive-level customer meetings, design reviews, and status updates.Build and maintain strong customer relationships as a trusted technical and strategic partner.Partner with Sales, Quality, and Operations to ensure program profitability, delivery, and performance metrics.Process Improvement & Mentorship
Develop and deploy standardized program management and NPI processes, templates, and governance tools.Lead lessons-learned reviews, CAPA initiatives, and strategic continuous improvement projects.Coach and mentor Junior and Mid-level NPI / Program Managers.Champion Lean, Six Sigma, and other operational excellence initiatives across sites.Qualifications
Bachelor's degree in Engineering, Manufacturing, or related technical discipline; MBA or PMP preferred.7-10+ years of experience leading complex NPI or program management initiatives in medical device, automotive, or advanced manufacturing.Proven record of leading cross-functional teams and managing multi-million-dollar program portfolios.Deep technical understanding of injection molding, tooling, validation, and regulatory compliance processes.Strong business acumen, financial management, and strategic thinking skills.Advanced proficiency in project management software (Smartsheet, MS Project) and ERP systems (IQMS, Epicor, or equivalent).Core Competencies & Traits
Strategic thinker with hands-on execution ability.Strong technical and manufacturing acumen.Customer advocate and trusted relationship builder.Mentorship and team development skills.Continuous improvement and systems-thinking mindset.Excellent communicator, problem-solver, and resilient under high-stakes, complex programs.