Engineer Plant Manager

ROEL LÓPEZ http://www.linkedin.com/in/roellopez**

915-***-**** abnwqc@r.postjobfree.com

*** ********* ***, ** ****, Texas 79912

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Plant Manager 18 years of progressive full accountability global best practice manufacturing experience

Proven talent for identifying core business needs and translating these into technical deliverables.

Extensive lean/six sigma experience as well as experience working with high volume assembly.

Establish the priorities, expectations and tone for performance management within the organization.

Collaborate with functional leaders on the Management Team to ensure the effectiveness of shared support

activities and implementation of appropriate policies, standards, procedures and best practices needed to

align the organization with regulatory requirements and the Corporate Missions and Values.

Successful at launching and managing projects to win new customers, generate revenue gains, increase

brand value, improving productivity, manufacturing throughput and improving quality.

Effectively manage relationship with unions, fortune 500 customers and vendors.

Industrial Engineer with MBA-Finance Strong sense of urgency. Fluent on English and Spanish.

LEADERSHIP CORE COMPETENCIES

Supply Chain Management Start-Up / Turn around /Change Agent Process Analysis and Reengineer

Multi-Sites Operations Strong P&L / Profit Improvement Safety Performance OSHA

Creative problem Solving Team performance optimization Leadership / Team Building

Project Management Prof. (PMP) TQS (Total Quality Systems) Continues Improvement Practices

KPI’s / Dashboards / Metrics TPS (Toyota Production System) Black Belt Six Sigma

APICS CPIM Education Value Stream Mapping Lean Six Sigma Manufacture

ISO 14001, QS9000, TS16949 MRP – ERP Systems TOC (Theory of Constraints)

EDUCATION

MBA – Finance, ITESM (Institute Technologic of Monterrey) http://www.itesm.edu/wps/portal/english

B.S. Industrial Engineer, UACJ (University Autonomy of Juarez)

CAREER PROGRESION

SIR (Mexico City) Plant Manager 2008 / 2009

Oversees all aspects on manufacturing operation business. Accountable on P&L. Directs, training and mentoring lean

six sigma manufacturing culture at all levels of the operations. Implement kanban material replenishment, KPI’s,

Dashboard, Visual management concepts, 5S and value stream mapping.

Accomplishments:

Reduce manufacturing lead time from 2 to 1 day, Increased WIP inventory turns from 39 to 67 per year. Reduce

manufacturing overhead and quality cost by 25%. Increased gross profit margin from 12% to 21%.

Change Agent; transforming a struggling business unit using kaizen principles that slashed hourly cost, boosted

on-time delivery, increase productivity, reduce scrap and increase customer satisfaction.

Instituted (QCPC) Quality Control Process Control and Visual Factory.

Improved employee knowledge of business operations and streamlined product flow.

LEGGETT AND PLATT (TN, USA and Juarez, Mexico) Plant Manager& VP Operations 2002 / 2008

Direct overall multi-plants National and International automotive, electronics and consumers goods manufacturing

operations with Injection molding, Extrusion blow molding, wire forming, Coating, Die cast, stamping and Assembly

facility process. Accountable on P&L, Production, Quality, Operation, HR, Engineer, Purchasing, Marketing and

Customer Service; Manage up to 500 employees with more than $50MM on sales, high volume production with

intensive travel. Main customers GM, NISSAN, DELPHI, LEAR & JCI. All facilities certified on ISO 14001, QS9000

and TS-16949.

ROEL LÓPEZ http://www.linkedin.com/in/roellopez03

915-***-**** abnwqc@r.postjobfree.com

600 Belvidere 10A, El Paso, Texas 79912

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Accomplishments:

Develop, Implement and Manage KPI’s (Key Performance Indicators) and Dashboards.

Transfer full business from Cumberland, Tennessee to Juarez, Mexico with zero customer compliance. Also

transfer productions lines from Ontario, Canada and Detroit, Michigan.

Designed and executed layout of 100,000 sq ft manufacturing facility.

Improve operational productivity by 29% through launch of team development programs; ergonomic workstations

increase efficiency 20%. Decrease operation waste on $800K engineer initiatives.

Standardize all process; systems and procedures result on 99.8% on-time delivery of production.

As result of key value engineer initiatives; reduce labor and material cost by 15% for product-handling changes;

Reduce frequency and severity of accidents by 98% in three years contributing to workers compensation on cost –

avoidance reduction of $500K.

Saved $100k annually on resin on injection molding areas, implementing SMED and created own tooling room.

Implement Lean manufacturing, Kaisen initiatives, Theory of Constraints, Lean Six Sigma projects and TPS

methodology (Toyota production System) with important reductions on labor (35% - 130 heads), overhead and

quality cost by 28% and improvement production efficiency from 85% to 95%, reduce scrap from 3% to 0.8%.

Decreased total inventory by 43% base through combination of supply chain management, master scheduling and

purchasing. Eliminate 80% of WIP with lean manufacturing tools. Move from Batch process to one-piece-flow.

DELPHI (Detroit, MI and Juarez, Mexico) PMO and Director of Operations Excellence 1999 / 2002

Member of Delphi Headquarters team to develop operations excellent culture on 48 facilities in Mexico. Direct

Program Management Office in Mexico operations. Standardize methods and procedures to execute project using PMI

(Project Management Institute) standards. Negotiate contract with different global vendors with great savings and

service improvement.

Accomplishments:

Selected to lead corporate team in developing and driving forward cost reduction initiative that will result in

$36MM saving in two years through process automation and contract negotiations with outsourcing global vendors

like EDS, IBM, AT&T, DELL, TELMEX, HP and MICROSOFT.

Orchestrated Development a PMO WEB tool to manage projects worldwide. Lead the implementation of project

management assessment tools and metrics for all project managers and project leaders in Europe, Mexico and US.

NPC (Lousville, KY, El Paso, TX and Juarez, Mexico ) Plant Manager 1992 / 1999

Direct and manage call center and data entry operation at NPC in Juarez, Mexico and Louisville, Kentucky, US.

1,800+ employees in three shifts 7x24. Fully accountable for P&L and business development. Main customers Airlines

(Southwest, Continental, US Airway and America West) and Banks (First USA, Advanta and Capital One)

Accomplishments:

Develop a generic tool to startup a new client in less than 24 hours. Before this tool the company spend at least

two month to startup new business. This tool allows us to increase our sales on 50% the first year (From $19MM

to $28MM USD).

Develop and implement applications to improve data entry. These systems allow the operators entry the

information from image and document zoom areas. Implement random entry to prevent employees don’t copy

private personal information (Credit Card Numbers, Names, Birthdays and Social Security).

Manage projects to Increase the process capacity with new technology. These projects allow us to reduce our

labor, improve our facilities, improve our efficiency, reduce hardware maintains contracts with vendors.

EDS (Juarez, Mexico and El Paso, Tx) Program Manager 1988 / 1992

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