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Summary
John is a dedicated Plant Manufacturing and Operations Consultant and Manager with over 25 years of expertise in a broad range of environments. Adept in implementation of continuous improvement projects including ISO, TS, & 5S initiatives, developing new procedures and protocols, increasing run-time levels, reducing outages, and ensuring strategic alignment via cross-functional communication. Proficient in creation of new reporting methods to strengthen work force capacity while training and crossing training 100+ direct reports. Fluent in Spanish and English.
Highlights
• 25+ years of “hands-on” Operations Management
• Continuous Improvement
• Process Improvement / Procedure Development
• Continuous Improvement Leadership
• 25+ years of “hands-on” Operations Management
• Continuous Improvement
• Process Improvement / Procedure Development
• Continuous Improvement Leadership
Relevant Accomplishments
- Successfully managed production for international automotive interior and automotive interior manufacturer; managed, trained, and mentored production supervisors – Assessed existing operations, determined gaps, and devised new initiatives to increase quality and profit levels, establishing new time management reports and increased time efficiency levels. Executed new production reporting standards departmentwide and set new production standards increasing production by 10%
- Spearheaded startup and setup of manufacturing facility for an automotive, boating, and furniture materials supplier via expert consultation, training, and cross-training of operators.
- Created new process for quality standards in quilt department improving quality by 14%. Implemented production reporting procedure across all departments setting new production standards resulting in an increase of run-time by 30%; Reduced outages to 0% via execution of Kanban systems for materials and consumables. Closed regulatory gaps, confirmed compliance, and sustained best practices by spearheading team for certifying machinery to Underwriter’s Laboratories (UL) standards. Designed new factory layout reducing material handling, installed all machinery, and created new maintenance program for foam cutting machinery
- Created new process for quality standards in quilt department improving quality by 14%. Implemented production reporting procedure across all departments setting new production standards resulting in an increase of run-time by 30%; Reduced outages to 0% via execution of Kanban systems for materials and consumables. Closed regulatory gaps, confirmed compliance, and sustained best practices by spearheading team for certifying machinery to Underwriter’s Laboratories (UL) standards. Designed new factory layout reducing material handling, installed all machinery, and created new maintenance program for foam cutting machinery
- Provided expert consultation for startup and rollout of international automotive interior manufacturer; implemented 5S procedure and Kanban systems reducing outages. Developed fixed asset inventory to identify discrepancies resulting in company savings of $20K. Designed factory layout to reduce material handling and installed all machinery and evaluated production staffing requirements leading to significant increase in productivity and profitability.
- Led quality team in implementing change initiatives to achieve greater results and guarantee consistent on-time delivery for an international manufacturer of automotive interiors. Managed and trained Quality Control Lab personnel and in-process Inspectors. Created and tracked in-process, supplier and customer return performance in order to reduce costs. Passed ISO-9001 surveillance audit and partnered with Plant Manager in China to implement TS-16949 in the U.S. Instituted quality initiatives to reduce customer returns by less than 2%; also improved receiving inspection procedures to reduce rejection rates to less than 1%. Continually developed process improvements to enhance efficiencies, including on-time shipping improvements from 65% to over 90% in Mexico Plant; also modified manufacturing processes to improve throughput by 100%.
Roles
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- Plant Turnaround Consultant
- VP Operations
- Plant Manager
- Production Manager
- Quality Assurance Manager
- Quality Engineer
Request Expert / Similar Expert
Click “request expert” for a free initial screening call with this expert or a similar expert regarding your expert consulting needs
To apply for this job email your details to dmagnani@maexecsearch.com
