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Summary
Operational Excellence professional with extensive experience in diverse industries including Automotive, Oil and Gas, Chemical, Electronics and Power Tools. Practical experience leading Quality, Continuous Improvement, Safety, Production, Maintenance and Manufacturing functions. Experienced facilitator leading multi-functional and multi-cultural teams. Certified Lean Six Sigma Black Belt. Skilled project mentor and trainer. APQP, Value Stream Mapping, Strategic Planning (Hoshin), Transactional Kaizens, Standard Work, Variation Reduction, Root Cause Analysis. ISO 9001, RC14001 and API Q1 implementation/certification. Budget management. Productivity improvement. Experience with supplier qualification and development; product transfers and starting up new manufacturing/assembly processes from scratch. 80/20 Strategy. Bilingual (English-Spanish).
Highlights
Relevant Accomplishments
Responsible of site P&L. In charge of Safety, Production, Maintenance, Quality, OpEx Engineering and Warehouse/Logistics functions. Accountable for critical sourcing strategy to re-shore critical supply chain.
Notable Accomplishments:
- Implemented strategy for repairs/warranties that led to $650K YoY COPQ reduction. Defined corrective actions for an additional $500K reduction.
- Sourcing strategy: LATAM sourcing potential. Negotiated deals that resulted in an additional $1.5M gross profit.
- Strategic plan to achieve 20% YoY EBITDA improvement.
- Lean transformation roadmap owner: Support $75M annual production plan with 40% less labor.
Responsible for design and implementation of Quality and CI strategies including Quality Management System and Lean Transformation roadmap in all 3 Kewaunee plants. Global supplier quality strategy deployment.
Notable Accomplishments:
- Definition of KPIs for all for all VSM functions that led to establish baselines for 3-year plan.
- Created supplier/part qualification process including supplier agreement document.
Responsible for site implementation of Akzo’s Leading Performance System (Operational Excellence) at Houston site and other Surface Chemistry sites. Mentoring green and black belts on cost reduction projects. Project manager for production volume transfer from sister site in Singapore and Asset Integrity improvement initiative. Policy Deployment owner. Support for implementation of ISO 9001-2015. RC14001 lead auditor.
Notable Accomplishments:
- CI project savings: $500K in FY2015, $3.8M in FY2016, and $4.2M in FY2017.
- Successful inter-continental transfer of new products resulting in 10% additional production volume.
Responsible for Quality across all value stream: suppliers, incoming inspection, assembly, testing, ISO and API certification as well as interaction with customers. Quality liaison with field locations.
Created the strategies and led the tactical execution of the continuous improvement initiatives for the drill bit services group. In charge of the Manufacturing Technology team including capital projects and tactical support.
Notable Accomplishments:
- 90% reduction on open customer complaints and 95% reduction on avg. open days.
- Lead/mentor Kaizen events that resulted on 45% YoY COPQ reduction.
- Achieved OSHA VPP re-certification with zero findings. Maintained API Q1 certification.
- Led the 3 level Hoshin planning sessions and maintained progress tracking.
Managed the Product Quality, Lean Six Sigma, Management Systems and Supplier Quality functions. LSS instructor for mid-career hires, White and Yellow belt training programs, including use of Statistical and Process Flow software. Accountable for implementation of Value Stream Map initiatives at critical Suppliers location. Team lead for PFMEA/PCP implementation at three of our critical suppliers. Perform ISO and process audits at supplier locations.
Notable Accomplishments:
- Implemented monthly Quality Steering Committee meetings including international locations.
- Reduced the number of field service quality incidents by 20%.
- Led/mentored 23 LSS projects during 2009 resulting in $1.35M savings.
- Standardization of engineering change process, reducing average closure lead time from 60 days to 18 days.
- Company representative at critical supplier locations. Responsibilities included process audit and validation.
Only member of Quality department, overseeing all aspects of Quality at the location: Document Control, Calibration, First article inspection, Process FPY, Internal and external corrective actions, Quality systems (including ISO audits).
Company representative on customer audits. Kaizen leader
Notable Accomplishments:
- Company representative for all government and other customer audits. During these audits I discussed, defined and eliminated features in our products not being used by our customers and therefore not critical for them but that implied an extra cost for the final product.
- Reduced the defects in the top runner line by 50% using Kaizen,the Red X, Pareto and Hypothesis Analysis tools.
In charge of Quality for assembly process at the Reynosa, MX plant and the warehouse in McAllen, TX. Managed 9 engineers and 15 technicians with ~$1M departmental budget. Areas of responsibility included: ISO, End of line testing, Process quality, Calibration, Incoming inspection and Metrology. Used LSS tools to design new cells, and improve productivity on current lines. Quality leader for transfer and startup of new assembly lines.
Notable Accomplishments:
- Led first ISO Certification for the Reynosa Mfg. plant and McAllen warehouse Incoming Inspection.
- 92% in-process failure reduction applying the DMAIC tools.
- Mentored and promoted 4 technicians to engineering positions and 2 engineers to management positions.
- Successfully transferred and started up 15 assembly lines during the 2004-2005 period using VSM and Kaizen.
Responsible for interaction with customers in audits, follow up meetings, rejections and any type of inquiry.
Company representative during reviews at customer assembly plans. Team leader for PPAP creation.
Notable Accomplishments:
- Served as liaison between GM assembly plant and the ALCOM operations.
- Created PFMEAs and Control Plans for new product lines.
- Reduced customer complaints for switches product line from 560 ppm to 15 ppm.
Team leader during the start up from scratch of a new Manufacturing plant in Mexico. Implemented Statistical Process Control, Capability Analysis, Process Control Plans and Process Failure Mode and Effect Analysis.
Notable Accomplishments:
- Transfer and qualification of product lines achieving 5% yield increase within the first 3 months of operation.
In charge of the facility maintenance and housekeeping as well as the segregation and disposal of hazardous and non-hazardous waste. Supervised a crew of 25 people.
Roles
- Operational Excellence Director
- Quality and Continuous Improvement Director
- Continuous Improvement Manager-Surface Chemistry
- Manufacturing Quality / HSE Manager
- Quality Systems Manager
- Quality Assurance Engineer
- Quality Manager
- Maintenance Supervisor
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