Manager Plant

Resume

Robert Saenz

***** ******** **** ***** • Shelby Township, Michigan 48315

586-***-**** • ************@*****.***

Manufacturing Executive

Multi-talented executive with impressive history cultivating top performing, low-cost, and high-quality organizations

across multinational locations for multi-million and multi-billion dollar manufacturing corporations. Position the company

for maximum business and revenue growth, developing and directing high-impact strategic plans. Using Lean, TPS and

Value Stream Mapping, operational performance is improved and employees and their commitment to excel are

engaged. Departments and resources are united at all levels with a common mission and goals.

• • •

Distribution Fill Rates Continuous Improvements

• • •

Labor Management Software Cycle Counting Value Stream Mapping

• • •

Inventory Accuracy Total Order Cycle Time Lean Manufacturing

• • •

Order Picking Metrics On Time Shipments Six Sigma

• • •

Monitoring Overstock Strategic Planning & Safety Policies & Procedures

• •

Positioning

Dock To Stock Cycle Time Problem Solving

• Global Business

• •

Tracking Picking Errors Team & Relationship Building

Reengineering & Development

• •

Transport Cost Per Unit Talent Management

• Start-Ups and turn-arounds

• Tracking Shipping Errors

Cadillac Products Automotive Company, Roseville, Mi • April 2012 – May 2013

Plant Manager of Southeast Michigan manufacturing and warehouse operation.

• Manufacture automotive watershields and acoustical products.

• Leading 6 direct reports / 80 people.

• Robotic manufacturing operations

• Direct and deploy resources for effective lean manufacturing performance.

• Launched new acoustical product for Chrysler without incidence.

• Other customers are Ford, GM, Nissan and Mitsubishi.

• Left company.

Truck Accessory Group, Woodland, Ca • January 2011 – April 2011

Contract Position / Interim General Manager of West Coast operations.

• Responsible for the manufacture of truck caps and tonneau covers for all makes.

• Led a team of 90 people / 160,000 sq / ft.

• Using Value Stream Mapping and Lean initiatives improved the plants overall performance.

• Resolved quality issues relative to process parameters and suppliers resin and gel coat products.

• Turned operation around from not meeting budget to exceeding budget.

• Improved employee morale by engaging them to achieve plant goals using Lean manufacturing, standardized work,

Value Stream Mapping and TPS.

Self-Employed Consultant, Knoxville, Tennessee • November 2008 – Dec 2010

• Worked as a cost reduction consultant with Expense Reduction Consulting.

• Researched and explored opening a franchised MAACO center, but could not obtain funding in 2009.

DURAKON INDUSTRIES, Knoxville, Tennessee • 2001 – November 2008 Vice President of Operations

$100M international manufacturer of thermoformed automotive products; clients include Ford, Chevrolet, Subaru, Honda,

and Buick. This company merged with Penda, the Durakon name was dropped.

Vice President of Operations / Durakon Industries December 2001-November 2008

• Manufactured plastic parts for OE and aftermarket.

Resume

• Spearheaded strategic plans to drive business growth, increase bottom-lines, and optimize performance of 3

manufacturing plants located in US and Mexico.

• Implemented LEAN and value stream

• Machining operations and robotics.

• DC center at Knoxville, TN. Measured picking accuracy, shipping errors, inventory turns, inventory accuracy, and

backorders.

• Performed cycle counting monthly

• Administered all P&L.

• Defined plant wide goals. Implemented organizational and professional development initiatives. Tracked product

launches and incoming sales.

• Established policies and procedures.

• Identified and directed opportunities to standardize procedures, and instituted lean manufacturing. Scheduled and

chaired multi-discipline meetings.

• Market went down I shut down the operations while they merged with a competitor.

Major Contributions:

• Launched plant manufacturing Chevy Avalanche in Lerma, Mexico, and established it as award-winning supplier and

#1 performing plant companywide within 1st year.

• Consolidated 2 US plants into 1 high-performance plant in Clinton, Tennessee.

• Minimized payroll costs, restructured staff; reduced salary headcount by 39 and indirect by 61.

• Saved $2.2M in annual costs, mitigating increasing resin prices by launching major program to locate and

utilize post industrial regrind in manufacturing recipe.

• Led all facilities to achieve TS16949 and QS14001 certification and compliance with ISO14001.

• Drove numerous improvements in quality, scrap, and efficiency, optimizing processes.

• Decreased Lerma’s RPPM from 10K to 60 within 1 year; maintained 25 RPPM for last 6 years.

• Lowered scrap rate from 50% to less than 10% soon after launching new paintfilm product line.

• Eliminated +30% of scrap from Ford railcap and +13% of scrap from GM door panels, reducing both to less

than 5%.

JOHNSON CONTROLS, INC. (JCI), Multiple International Locations • 1988 – 2001

General Plants Manager

$20B multinational manufacturer of high-volume domestic automotive seat covers; clients included Ford, GM, Chrysler,

and Jeep.

General Plants Manager/Johnson Controls – Mexico • 1996 – 2001

• Formulated and directed execution of strategic plans to grow and optimize +$400M multi-plant automotive trim-cover

operation in Mexico, and warehouse and lamination operations in Texas.

• Developed and implemented 3-year financial plan annually.

• Established goals and key performance metrics.

• Participated in new product launch and capital expense meetings.

• Supervised 4 plant managers, and directors of engineering, quality, materials, and information systems, Regional

Controller, and Director of Human Resources managing.

• Grew production from $80M to +$400M in sales, opening 3 additional plants in Juarez, Mexico; interviewed,

selected, and strategically placed all leadership talent.

• Captured +$6M in 1st year savings, obtaining designation as Six Sigma Champion.

• Centralized US and Mexican customs, MRP, and LAN systems, designing framework.

• Initiated Ford contract in Mexican facility, achieving 2,000 vehicles per day on plateau launch.

• Maximized efficiency, implemented Kan-Ban style pull system for shop floor scheduling and standardized visual

management in all plants.

• Managed a central DC / Warehouse in El Paso for Johnson Controls Seating. Receiving raw material and

shipping to plant in Mexico. Received finished product that was shipped to other JC plants.

• Measuring order accuracy, on time deliveries and dock to stock cycle time.

• Recognized as 1st operation to utilize Value Stream Mapping in identifying Lean opportunities.

• Created open-work collaborative team environment across all plants, instilling participative management style within

and between each plant.

• Obtained QS9000 and TS16949 certification for all plants.

• Provided resource assistance for launches of plants in Saltillo, Brazil, and Argentina.

• Recruited to Durakon.

General Plants Manager/Johnson Controls – Western Europe • 1994 – 1996

• Created and led implementation of short- and long-term strategic business, operational, and financial plans for

automotive trim-cover operations in Belgium, Portugal, and UK.

• Responsible for 3 warehouse operations and inventory. Measured inventory turns, and freight cost metrics

• Oversaw performance, utilization, and safety of 1.600 employees.

Resume

• Supervised plant and program managers.

• Launch a new plant in England.

• Pioneered trim plant in Mansfield, UK, and established systems integrated with company.

• Reengineered business, transferring product from Belgium plant and to operations in the UK and Czech Republic.

• Optimized all aspects of operations in Portugal, instituting multiple performance improvements.

• Improved quality from 5,000 to 1,000 RPPM and efficiency from 70% to 80%.

• Initiated Ford contract across 3 plants simultaneously, achieving 6,000 vehicles per day on plateau launch for

facilities in Europe.

Plant Manager – TechnoTrim / Johnson Controls • 1988 – 1994 Stockton, CA

• Oversaw and coordinated all aspects of California operations for joint venture with Tachi-S of Japan; produced seat

covers for Toyota and Geo. Managed all P&L.

• Supervised 250 personnel with 5 direct reports.

• Cell Manufacturing

• Positioned plant as most profitable operation companywide.

• Designed and launched major improvement program, “Management Operating System.”

• Cut inventory days from 20 to less than 5 and improved quality from 5,000 to 300 PRRM.

• Ran a KANBAN on the existing volume of cut inventory lying about the plant. I was able to improve total

inventory from 25 day days to 10 days.

• Implemented cycle counting monthly.

• Increased on-time delivery from 85% to 99% and efficiency from 65% to 100%.

• Reduced turnover from 50% to 7% annually.

• Improved picking accuracy from 85% to 98%.

• Promoted and transferred to Europe.

Plant Manager - Western of Texas (3/87 to 2/88)

• Accountable to the Vice-President of Manufacturing.

• Total profit and loss responsibility for the operation of a wire harness assembly plant.

• 50 employees / 3 direct reports.

• Cell Manufacturing

• Provide direction and guidance to production, quality control, materials, engineering and maintenance personnel.

• Evaluate personnel requirements and equipment needs.

• Recruited to Johnson Controls.

Independent Consultant (8/86 to 2/87)

• Western of Texas: Developed cost routing sheets for quoting new products. This evolved into a

full time position as a Plant Manager.

• Electromechanical Systems: Developed shop floor scheduling system and implemented quality

control procedures for a machine shop operation.

General Manager Delco, A/C and Corvette Operations - Auto Assemblies Inc. (10/84 to 7/86)

• Accountable to the Vice-President of Auto Assemblies.

• Total profit and loss responsibility for the operation of three harness assembly plants and one

warehouse operation.

• Responsible for pricing, costs, sales and production.

• Develop management staff to handle businesses.

• Directed the activities of two plant managers and one production manager.

• Previously, Director of Engineering and Quality Control.

• Lost contracts with GM and I was laid off.

Product Manager Anesthesia Equipment - Ohio Medical Products / OHMEDA

(El Paso 12/80 to 10/84)

• Responsible for start up of new electronic controlled anesthesia machine using “just in time”

techniques and management philosophy.

• Operated as a plant within a plant, provided direction for production and inventory control,

purchasing, quality control, manufacturing engineering and production.

Resume

• Previously, Plant Production Manager.

• I was recruited.

EDUCATION & PROFESSIONAL DEVELOPMENT

Bachelor of Science in Mechanical Engineering, University of Texas, El Paso, Texas

Six Sigma Champion • Lean Institute Training • Learning to See Program

Member of: Society of Manufacturing Engineers (SME) • Society of Automotive Engineers (SAE)

Society of Plastics Engineers (SPE)

AWARDS & HONORS

Durakon: Ford’s World Excellence Gold Award for Best Supplier of the Year • Ford Q1 Award

Honda’s Award for Best VA/VE Submission • GM’s Top Focus Most Improved Supplier

JCI: Chairman’s Award for Best Plant in Customer Service • Gold Award for Safety

Chairman’s Award for Plateau Launch of Ford Contract

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