Ivan Zavala

***** ***** ****** ** 281-***-****

Cypress, TX 77433 acvind@r.postjobfree.com

PROFESSIONAL PROFILE

Structured, results oriented Manufacturing and Operations Executive effective in maximizing profits and delivering quality products to customers with 100% on time delivery. 15 years of exceptional cost reduction while enhancing customer satisfaction. Consistent track record of achieving over 50% Gross Margin by improving productivity and material/service cost negotiations through P&L management. Unique interpersonal and motivational skills coupled with commitment to excellence in meeting and exceeding company goals and objectives. BACKGROUND SUMMARY

• Strategic Operations Leadership • Supply Chain Optimization • Policy Deployment

• Advanced P&L Management • Continuous Process Improvement • Process Engineering

• Vendor Contract Negotiations • Accelerated Operations Growth • Product Development and R&D

• Import and Export Compliance • Resource Mentoring • Toyota Production System Expert

• Quality Assurance and

Regulatory Compliance

• Accelerated Lean Manufacturing

and Six Sigma Transformation

• State and Federal Environmental

Compliance

TECHNICAL SKILLS

• Microsoft Access • Advanced Excel Programming • Minitab

• SAP/ERP Systems • EPA TRIMEWEB • Statistical Process Control

• Microsoft Office Suite • Innovative Elastomer Knowledge • Control Plan Development PROFESSIONAL ACCOMPLISHMENTS

UTEX INDUSTRIES, Houston, TX 2008 – 2016

Plant Manager (2013-2016)

Corporate Lean, Quality and EHS Director (2008-2013) Created a new manufacturing facility within the Utex organization to further expand product offerings. New facility resulted in $30 million in additional sales annually. Served as the key contributor in restructuring and improving operations through process improvements. Led projects that resulted in significant increase in annual sales from $65M to $160M in 4 years and $200M in 6 years Worked closely with General Managers, CEO and CFO to evaluate all organizations within Utex. Utilized data to select quality, efficiency indicators and benchmark data from world class facilities to make manufacturing improvements. Analyzed data for patterns and trends in product production, delivery and opportunity for improved quality and efficiency. Constantly performed follow-up evaluations of data and organizational performance to ensure consistent improvement; and effectively communicated results of improvement efforts and on-going performance measures to executive management.

Trained and educated the organization's staff to promote good quality practice. Ensured compliance with all applicable laws and regulations. Communicated effectively and proficiently to staff regarding process improvement initiatives. Managed 100% success rate on the development, implementation and certification in ISO 9001:2008 and AS9100. Worked collaboratively with diverse teams to develop efficient and actual “world-class” processes, utilizing techniques such as Lean Manufacturing/Six Sigma, DMAIC, PDCA, 5S, SPC, TQM, OEE and Kaizen Events.

Managed the integration of two multi-million manufacturing plant acquisitions. Completing the assimilation on schedule with no disruption to key business processes and saving $5 million in redundant operating costs. FERGUSON BEAUREGARD Tyler, TX 2007 - 2008

Director of Operations and Supply Chain

Optimized Supply Chain management through inventory Kanban and Pull Systems. Project resulted in 25% reduction in inventory and improved plant inventory turns from 9 to 16 in 6 months across 10 field locations.

Accomplished 6 Kaizen events that resulted in significant improvements on bottom line and corporate metrics. Incorporated a Field Service delivery ticket system that uploaded on the company server remotely from field locations that decreased invoicing time to customers from 3-4 weeks to 24 hours ENPRO. PLASTOMER TECHNOLOGIES, Houston, TX 2003 - 2007 Operations Manager

Implemented cost cutting programs. Reduced 20% of the workforce, redesigned work processes, automated purchasing and warehousing, eliminated 25% of the vendors, and cut inventory by 50%, cumulatively saving more than $4 million annually. Achieved numerous production records during a period of extremely high sales demand and played a pivotal role in delivering record profitability of 55 % gross margins. Negotiated raw material contracts for the entire Corporation. Efforts reduced $5 million dollars by consolidating and leveraging purchasing buying power with vendors across the United States and Europe. Increased inventory turns from 4 to 18 by implementing Pull Production across the entire Supply Chain Process and creating stocking locations in Houston, TX.

ENPRO, STEMCO, Longview, TX

Process Engineer

1999 - 2003

Developed, documented, implemented and maintained ISO 9001:2008 and TS 16949. Created, validated and maintained efficient and effective programs for SPC, supplier/vendor qualification, source inspection, component evaluation, and component sampling and approval

Coordinated and effectively trained department staff. Training included Production, Assembly/Installation Operators, and Quality and Test Technicians in Lean Manufacturing Projects and Kaizen Events Developed and engineered processes. Introduced 6 new innovative product lines in the Heavy Duty Automotive Industry that contributed to over $20M in sales EDUCATION

Bachelors of Science in Mechanical Engineering, THE UNIVERSITY OF TEXAS, Austin, TX 1999 TRAINING

• Procurement and Supply

Chain Negotiations

• ASQ Supplier Certification

Process Expert

• Internal Auditor 9001:2008,

TS 16949 and AS 9100

• Certified Lean Manufacturing

Black Belt

• EPA Toxic Release Inventory • U.S. Customs Audit & Compliance Assessment

• Tariff Classification under the

Harmonized System

• Effective Root Cause

Analysis and Corrective

Action

• EPA Title V Air Permitting

• TCEQ Water Quality and Storm

Water Pollution Prevention

• Failure Mode and Effects

Analysis (FMEA)

• TCEQ Hazardous Waste

Management and Pollution

Reduction

• Classification Under Schedule

B

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