Industrial Reliability and Operation Manager (Production and Maintenance)

Dynamic, goal driven and results oriented multilingual (English, Spanish, Romanian) Mechanical engineer with Master in Reliability, with 14+ years of Managerial experience in Industrial Operations (Production and Maintenance), Process control, Quality Management System: Quality assurance, policies, documentation, procedures; Supply Chain improvement: Scheduling, Planning, warehouse management and dispatching; Lean manufacturing and six sigma, Cost reduction, Project management, Manufacturing and Industrial engineering, automation and robotics, Purchasing.

Leading, Coaching, consolidating teams to obtain results through developing high level of competencies of Analytical/Researching skills, identifying continuous improvement opportunities, setting challenging goals, organizing action plans using KPIs and accountability. Consistently able to manage Multiple Priorities and Multitasking, in multicultural environment (culture and gender), focused Route Cause analysis and Problem-Solving with Creativity, Teamwork, Leadership, Flexibility and Adaptability, keeping the vision to obtain the most advantageous and profitable solution. Constantly Learning, Teaching and Feedback at all levels. Wide experience supervising union and non-union employee.

Operational Management

Strategic Planning

Project Management Proficiency

Process improver

Problem Solving

Team Leadership

Quality Commitment

Solid Business Acumen

Customer Service Oriented

Team player and Developer

Cost and Budget Accountable

Organizational Abilities

Cost Reducer

He never fails to get an overview of the business while planning

“Jose L Osuna, Audit Manager”

Vision to integrate all aspects of effective maintenance organization

“Daniel Anderson, Plan Manager”

Flexibility and dynamism a production manager can provide to their customers

“Federico Gianinnetto, Sales Director”

PROFESSIONAL EXPERIENCE

ORION ENGINEERED CARBONS – Franklin, Louisiana, USA (Feb 2015 – Current)

Chemical plant producing Carbon Black

Plant Reliability Maintenance Manager

Organize maintenance strategy based in Reliability, transforming the culture to integrate Preventive and Predictive maintenance, stablishing Policies and Procedures to solve of chronic problems and downtime, using Failure Analysis (FA), Cause Mapping (CM), Finite Element Analysis (FEA), Planning and scheduling activities, developing SAP, justifying and executing CAPEX project.

-Achievement on Utilization: Total up time rise 13% to 95.4%, and 96.5%, first and second years respectively, due to FA & CM to eliminate chronical problems, emphasizing preventive and predicting.

-Achievement on Cost: 1.4MM$ saved due to up-time improvement, reduce off-spec product, and lower material consumption.

-Capex Execution: 205% increase capex execution, up to 5.6MM$ 2017.

TENARIS HYDRIL USA – Houston, Texas, USA (Sep 2012 – Jan 2015)

Integrated Steel Pipe maker, OCTG, Oil & Gas, Automotive, Industrial, Mechanic and Structural Applications

Plant Maintenance Manager of Premium Threading (and Manufacturing support)

Responsible to manage Strategy, Organization, Budget, Policies and Procedures to ensure compliance of indicators such Safety, Efficiency, Productivity, Cost, Reliability, Facility and Process Improvement, and employee development. Implementing Lean Manufacturing Technics (5S, Muda, PDCA, RCA, SMED, etc). Budget of 46 direct Employee, + 16 third parties services, 6 to 8MM$ of variable expenses, 3MM$ of CAPEX and 2.5MM$ for Extraordinary Maintenance.

-Achievement on Costs: Save 1.6MM$/year variable expenses, through projects of: Energy consumption reduction plan (re-engineering and optimizing equipment); developing internal talent to insource expensive services, looking for Cost-Effectiveness. Achieving 12% reduction during 1st year.

-Achievement on Utilization: Reducing Non Operative Downtime indexes, 2% in threading lines, and an average of 13.4% in Swage, Phosphate, Buck-on and Dopeless. Through developing team skills for reliability maintenance and Lean Manufacturing technics.

-Special Manufacturing projects: 10 CNC retrofits, redesign 700To press and tooling optimization, Automation of phosphate process, re-engineering transportation trolleys; as well operator work station, Bottleneck elimination, Single minute Exchange die (SMED), operator handling optimization, etc.

-Achievement in HR: Create and organize a maintenance functional structure and Developed Employees’ skills for planned maintenance, maintenance Engineering, Workshop sub-assemblies, together with special project of SAP-PM module implementation.

TENARIS Silcotub – Zalau, Salaj, Romania (Sep 2008 – Aug 2012)

Operation Plant Manager of Cold Drawn and Automotive Component Center (Apr 2010 – Aug 2012)

Develop a new production capacity in CD plant and two component center facilities, including new products and processes. Establishing and implementing a Quality System, developing Lean Manufacturing technics (Poka-yoke, SMED, Standardized Work, OEE, etc), Managing a Project to develop Supply Chain with Level Scheduling, Andon, Continuous Flow, JIT (purchasing of row materials and consumables), Kanban (reduce stock levels), and Muda (waste reduction); as well as investment and CAPEX to achieve a yearly production capacity of 24000 (M)To C.D.S. and 12000(M)To of components. Additionally, overseas performance of Safety, Quality, Scheduling, certification of ISO TS 16949, production compliance and Cost-Effectiveness, with 192 employees.

-Achievement on Efficiency: Lead action plan of Six-Sigma and Lean manufacturing, to increase cost-effectiveness (improve HH/Ton in 12%), productivity improves 11.3% on average Utilization, and increase productivity of 37% in NDT-UT line (Bottleneck).

-Achievement on compliance: Compliance was raised up and kept over 98%, Quality Gold supplier by Caterpillar, and 99% overall rating from GKN, Autoliv, Lemforder, Renault-Dacia, TRW.

-Special Projects: Define and lead automation of drawing benches, Ultrasonic Test and finishing lines.

-Special Projects: Lead equipment selection, specification and startup of a robotic line for Airbags.

-Special Projects: Project manager for installation of a second line of hydraulic cylinders with robotic welding and robotic dimensional checking.

Manager of Industrial Utilities and Services (Sep 2008 – Mar 2010)

Responsible for production of industrial fluids as: Compressed Air, Cooling and Industrial water, Steam and Hot Water, oxygen and Nitrogen. Budget compliance, Environment and Safety, productivity, cost, reliability, and employee’s development. Services include: High Tension Power Distribution, power transformation to medium tension, Crane’s maintenance and workshop areas; with a Budget of 37 direct employee, 1,2MM$ of variable expenses, 0.5MM$ for Extraordinary Maintenance, invested 3.5MM$ on improvements.

-Achievement on HR: Create and manage a reliability maintenance plan for industrial services, including Rotary Equipment Workshop (DC motors for Hot Rolling Mill), and Mechanical sub-assemblies workshop.

-Special Project: Manager to restore efficiency, capacity and Automation of Heat Recovery Plant to generate Steam. Achieving double capacity, rich 73% of Thermal efficiency and reducing 20% headcount.

-Special Project: Justifying investment, lead equipment selection, and Start-up of Thermic Plant to insourcing Steam and Hot-water generation. This project save 73% in cost of BTU/h (over 1.2MM$/year).

-Special Project: Create and organize the sector of Central Industrial Services, reducing 37% headcount to cover same activities, after automation and re-organization.

TERNIUM SIDOR – Puerto Ordaz, Bolivar, Venezuela (Aug 1998 – Aug 2008)

Maintenance manager (Sep 2006 – Aug 2008)

Responsible to manage Strategy, Organization, Budget, Policies and Procedures to ensure compliance of indicators such Safety, Efficiency, Productivity, Cost, Reliability, Equipment Improvement, and Employees Development. Budget for 453 lifting equipment, Employee: 164 direct and 64 third parties, 6 to 8MM$ of variable expenses, 3MM$ of CAPEX and 7,2MM$ for Extraordinary Maintenance.

-Special Project: Manage electric conversion of DC to AC, in cranes of Hot rolling mill, portainer cranes, and automation of steel shop crane. Reducing down time in 63% and saving 1.3MM$/year.

Manager of Reliability/ Manufacturing Engineering Department (Sep 2003 – Aug 2006)

-Achievement on Efficiency: Pickling lines & coating have reduced 37% & 18% of non-operative downtime index due to revamping of gear boxes (including control loop automation).

-Achievement in Cost: An average of $275K/year, were saved due to equipment improvement.

Reliability Engineer Planning Maintenance Sector (Jun 2001 – Aug 2003)

-Achievement on Efficiency: Reliability project to develop a maintenance plan based in condition to reduce Non Operative downtime. Starting from 13.2% of possible utilization, up to 4.1% in two years.

-Special Project: Redesign the Emulsion System to reduce high consumption of pump’ spare parts. At the end, Time between failure was extended from 6 month to 2 years, Savings 78K$/year (73%).

Purchaser of Investment (Aug 1999 – May 2001)

Project Manager of Engineering Department (Aug 1998 – Jul 1999)

EDUCATION

-Executive Development Program

LSU Executive Education - E.J. Ourso College of Businessl.

-Intensive Management Development Program (by Tenaris University)

Austral University, Rosario, Argentina, 2011. Partner of Harvard Business School.

-Specialization in Mechanical Design and Industrial Engineering

-(Equivalent MS-Industrial Reliability)

Simón Bolívar University, Caracas, Venezuela, 2004.

-Mechanical Engineer (BS)

University of Carabobo, Valencia, Carabobo, Venezuela, 1998.

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