Juan C. Macias Contact

***** ******* ***. *., ******, MN 55378 952-***-**** (Home), 612-***-****

(Cell)

acgj28@r.postjobfree.com

Objective

To be part of an organization that prides itself on the quality of its people,

products and processes. To apply a continuous improvement philosophy through all

aspects of quality and manufacturing with focus on resolving technical issues,

improving process capabilities and meeting customer's expectations.

Education

2000 to 2006

Master of Science - Manufacturing Systems

University of St. Thomas, St. Paul, MN

Graduated Magna Cum Laude - School of Engineering

1994 to 1998

Bachelor of Science - 1) Manufacturing Engineering, 2) Product Development

University of Wisconsin - Stout, Menomonie, WI

Graduated Magna Cum Laude - School of Industrial Technology

Work Experience

2012 to Present - PGC Inc., Edina, MN - manufacturer of engineered products for

gasketing, sealing, sound/vibration and EMI & RFI needs (Winner of the "2014

Manufacturer of the Year award" - MN Manufacturers Alliance)

Director of Manufacturing and Quality

Oversee day-to-day Production, Quality and Manufacturing Engineering operations;

work closely with Customers, Supply Chain, Marketing & Sales and Design Engineering

to ensure that quality, on-time delivery and production goals and metrics are met.

Champion Continuous Improvement efforts throughout the organization including the

development and monitoring of company metrics and goals; facilitation and ownership

of company-wide improvement projects including Kaizen events, A3 Projects,

Failure/Root Cause Analysis, 5S projects, SPC & Capability Studies, DFSS, DFMA, FMEA

and provide expertise and training on 6 Sigma tools, techniques and best-practices.

Responsible for leading the Quality, Production and Manufacturing Engineering

functions including supervision of Engineers, Supervisors and Technicians; provide

direction and guidance to ensure that outcomes are consistent with organizational

business, strategic plans and yearly goals and objectives. Ensure that systems are

in place so appropriate Corrective/Preventive Actions are taken to address any

nonconformance.

Member of the organization's Executive Team; tasked with the planning and execution

of strategic and tactical plans for the Company including: Quarterly and Yearly

goals, funding and budgeting for capital equipment projects, expansion and growth

activities as well as staffing and allocation of resources. Provide input with the

overall values, culture, structure and direction of the organization.

Responsible for the development, implementation and maintenance of the Aerospace

AS9100C Standard as well as improving the robustness and efficacy of the ISO9001

Quality Management System within the Company.

Direct the proactive development and implementation of policies and procedures to

ensure compliance with applicable laws, rules, and regulations.

2008 to 2012 - Beckman Coulter Inc., Chaska, MN - manufacturer of Medical

Laboratory/Diagnostic Instruments

Sr. Technical Operations Engineer (Manufacturing Engineering) - Instrument

Manufacturing

To act as the liaison between R&D and Manufacturing for a $400+ million new

Molecular Diagnostic project. Responsible for setting a production environment

capable of commercializing complex electro-mechanical systems including equipment,

tooling, safety, ESD control, packaging and floor layout.

Oversaw day-to-day engineering & manufacturing support; worked closely with Quality

Assurance and the Supply Chain organization to ensure that production goals are met.

Developed, maintained and reported key metrics to the Site Leadership Team. Lead the

Technical Operations team for the project; mentor junior Engineers, Technicians and

Assembly Staff to ensure consistent and stable processes and deliverables.

Responsible for instrument DFMA, FMEA, pFMEA and Risk Assessment activities. Lead

cross-functional efforts for manufacturing operations related to increasing

product/process quality, throughput, yield and line efficiency. Initiated, reviewed,

approved and implemented Change Orders and related documentation.

Investigated and resolved production and performance issues by using statistical

tools and techniques. Performed hardware and process verifications, validations and

characterizations following FDA and ISO guidelines. Investigated and implemented new

manufacturing methods, processes, capital equipment, fixtures and tools.

Responsible for designing and implementing the infrastructure for an internal

automated SPC system; focused on collecting, analyzing and reporting production data

in order to increase first pass yield, process capability and quality metrics.

2004 to 2008 - Stratasys Ltd.., Eden Prairie, MN - manufacturer of 3D Printing and

Additive Manufacturing Systems

Manufacturing Engineer II -FDM Division

Responsible for production operations of complex electromechanical systems: high-end

rapid prototyping and rapid manufacturing systems. Responsible for day-to day

engineering and manufacturing support for the assembly line.

In charge of the implementation and maintenance of methods, processes and equipment

related to quality and performance specifications, throughput demands and

manufacturing cost requirements.

Actively participated in cross-functional teams associated to new product

development and Continuation Engineering improvements. Provided manufacturing

technical support and expertise including DFMA and FMEA input during design and

development cycles.

Provided expertise and assistance to resolve and control manufacturing quality

issues including MRB processes, Statistical Process Control activities, Continuous

Improvements initiatives, Six Sigma projects, cost reduction projects,

fixturing/tooling design and material flow studies.

Acted as the Team Lead for cross-functional efforts towards the elimination of

early-life field failures. Performed failure analysis activities to determine root

cause and implement corrective and preventive actions including design changes and

improved testing.

2001 to 2004 - Valmont Industries, Farmington, MN - manufacturer of Fabricated Metal

Products

Manufacturing Engineer & ISO Quality Manager - Structures Division

Created, implemented and maintained the Quality Management System - ISO 9001:2000,

including the authoring of all procedures, supervision of Quality Technicians and

training of all related staff. Responsible for the Metrology function within the

company.

Championed the implementation of Lean Manufacturing Activities, Six Sigma projects,

Kaizen Events, Gemba walks, 5 S Workplace Organization, Continuous Improvement

initiatives, Best Practices initiatives, Safety and Ergonomic improvements.

Researched and analyzed capital equipment and expansion projects in order to

increase productivity and maximize profits. Performed ROI studies to justify related

expenses/returns.

Troubleshot production problems, investigated and implemented solutions on issues

associated with manufacturing processes, equipment capabilities, tooling/fixtures,

print tolerances and manufacturability.

Responsible for welding operations including the certification of processes and

personnel to comply with performance, quality standards and customer's requirements.

1997 to 2001 - Kohler Company, Kohler, WI - manufacturer of Kitchen, Bath and Engine

Products

Industrial Engineer - Cast Iron Division

Provided production support to the Work Measurement & Standards Dept.; evaluated,

justified, managed and implemented process improvement programs and projects.

Designed, developed and implemented new methods, processes and equipment to improve

grinding and machining activities to reduce scrap and minimize idle time.

Created and modified tooling and fixtures using CAD systems (AutoCAD and ProE).

Performed studies of motion-involved activities and established standard production

rates to improve the efficiency and performance of the Division.

Certifications & Memberships

Six Sigma Green Belt Certificate - Employers Association Inc., Stratasys Inc.

ISO 9000 Certified Quality Auditor, Lead Auditor- Det Norske Veritas/Valmont

Industries

GD & T Level II Certificate & Advanced Application and Analysis - International

Institute of Geometric Dimensioning & Tolerancing

DOE / Anova Tools & Practices Certificate - Beckman Coulter Inc., Stratasys Inc.

Design for Manufacturability and Assembly (DFMA) Certificate - Minnesota

Manufacturers Alliance

Society of Manufacturing Engineers - Senior Member, past Executive Member

Project Management Certificate - Practices, Tools and Principles - The Lewis Project

Management Institute, Kepner-Tregoe Inc.

Certified Welding Inspector - Canadian Welding Bureau & American Welding Society

Rapid Technologies & Additive Manufacturing Association (SME) - Member

American Foundry Society - Member

Practical Ergonomics Certification - Minnesota Safety Council

Certifications & Memberships

Six Sigma Green Belt Certificate - Employers Association Inc., Stratasys Inc.

ISO 9000 Certified Quality Auditor, Lead Auditor- Det Norske Veritas/Valmont

Industries

GD & T Level II Certificate & Advanced Application and Analysis - International

Institute of Geometric Dimensioning & Tolerancing

DOE / Anova Tools & Practices Certificate - Beckman Coulter Inc., Stratasys Inc.

Design for Manufacturability and Assembly (DFMA) Certificate - Minnesota

Manufacturers Alliance

Society of Manufacturing Engineers - Senior Member, past Executive Member

Project Management Certificate - Practices, Tools and Principles - The Lewis Project

Management Institute, Kepner-Tregoe Inc.

Certified Welding Inspector - Canadian Welding Bureau & American Welding Society

Rapid Technologies & Additive Manufacturing Association (SME) - Member

American Foundry Society - Member

Practical Ergonomics Certification - Minnesota Safety Council

Software Competencies

Solidworks, AutoCAD, ProE

JMP (Statistical Software), StratSTAT, NWA (SPC control software)

3dVIA Composer (Work Instructions - Dassault)

wIntegrate, AS400, Macola (ERP/MRP packages)

Microsoft products: PowerPoint, Project, Excel, Word, SharePoint, Outlook

Certifications & Memberships

Six Sigma Green Belt Certificate - Employers Association Inc., Stratasys Inc.

ISO 9000 Certified Quality Auditor, Lead Auditor- Det Norske Veritas/Valmont

Industries

Leadership and Supervisory Certification - MN Manufacturer's Alliance

GD & T Level II Certificate & Advanced Application and Analysis - International

Institute of Geometric Dimensioning & Tolerancing

DOE / Anova Tools & Practices Certificate - Beckman Coulter Inc., Stratasys Inc.

Design for Manufacturability and Assembly (DFMA) Certificate - Minnesota

Manufacturers Alliance

Society of Manufacturing Engineers (SME)- Senior Member, past Executive Member

American Society for Quality (ASQ) - Member

Project Management Certificate - Practices, Tools and Principles - The Lewis

Project Management Institute, Kepner-Tregoe Inc.

Certified Welding Inspector - Canadian Welding Bureau & American Welding Society

Rapid Technologies & Additive Manufacturing Association (SME) - Member

American Foundry Society - Member

Practical Ergonomics Certification - Minnesota Safety Council

Languages

Spanish (native); can act as a simultaneous translator in English/Spanish

Military Experience

Second Lieutenant in Infantry - Ecuadorian Army Reserves

Addendum to Juan Macias' Resume (8/20/14)

Results of Continuous Improvement projects at PGC during the last 18 months

Obtain AS9100C Aerospace Certification for the Company

Research, develop and implement all required processes and documentation to obtain

certification. Audit was successful, PEARs implemented, 2 minor non-conformances

issued.

Develop and Implement a Project Management Tool to be used company-wide

Selection, training and implementation of the A3 process as the main tool. 21

employees trained, 14 formal projects completed or in-process. The deployment of

this tool was critical to the strategic and tactical goals of the company and was

a decisive factor in being awarded the "2014 Manufacturer of the Year Award" by

the MN Manufacturers Alliance Organization.

Manufacturing Operations Re-structure

Comprehensive re-structure of manufacturing operations with scalability and

sustainability and efficiency in mind. Creation of 3 Value Streams, selection of a

tier-2 leadership team, creation and implementation of a new technical support

department (Manufacturing Engineering), definition and implementation of an

escalation process. Implementation of daily production meetings, visual management

tools and emphasis on communication and collaboration between shifts.

Gross Margin goals for Team 1, 2 and 3 (Financial Project for Account Managers)

Developed 3 separate projects for each of the Account Managements teams in order

to improve Gross Margin (GM) expectations to support Revenue goals. Through a

combination of administrative and production efficiencies, improvements in the

communication channels and price increases, 2 out of the 3 teams achieved their

goals (% GM is confidential).

MRB Process and Area Revamp

The Material Review Board process lacked robustness and accountability which

resulted in Open Non-Conformances lingering for months. The actual MRB Area was

much disorganized and had no means of providing visual status of the current

condition. A new process was developed and new roles and responsibilities defined

and documented. Non Conformances are now being closed in days or weeks rather than

in months. New visual management tools have been implemented and the area is

clean, has shelves and locations for the different types of NCR's and a status

board was created to provide a quick and accurate reflection of such processes.

Tools and Dies lacking structure and Traceability (AS9100 requirement)

Tools, dies and fixtures were not documented and lacked traceability requirements.

A new Electronic Software Application was developed in-house to address those

needs. "DieMonD" (Die Monitoring Database) has 17 different fields that provide

traceability and query functionality to be used by Production staff as well as

Engineering and Customer Service functions. This Database allows accurate and

immediate tooling-information that was previously non-existent or would have taken

operators and technicians hours to compile.

Order Entry Standardization

The Process used by Customer Service for entering customer requirements into the

internal ERP system was not well defined, understood or followed creating

confusion and non-conformances to our customers. A new system was developed and

implemented resulting in standards practices providing uniformity and consistency

to the information flow down. Service Quality metrics have gone up from 98.5% to

99.8% as a result.

Engineering Change Order (ECO) Optimization

The ECO process lacked robustness and had steps that were out of sequence or

missed by the reviewing staff, this resulted in very costly mistakes (totaling ~

$150K in materials and labor per year). A new system was devised placing

manufacturing engineering support during the early stages of new product

development as well as embracing DFMA and manufacturability indexes. Checklist and

guidelines were created based on the function of signatory staff and processes

were updated reflecting current practices.

New CAPA (Corrective/Preventive Action) system for QA

In Progress. Status = On-Track

OTD (On-Time-Delivery Improvements) for Manufacturing Operations

In Progress. Status = On-Track

Manufacturing Training Optimization Project

In Progress. Status = On-Track

Equipment Justification and Implementation Process

In Progress. Status = On-Track

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