Jose Jesus Garcia

**** ******* ***** *** *, Douglas AZ 85607

1-520-***-**** Main phone, 1-520-***-**** Alternate phone

ac2cze@r.postjobfree.com

Senior Manufacturing/Industrial Engineer with 16 plus years’ experience on the continuous improvement of manufacturing processes to maximize profitability of the operations.

PROFESSIONAL EXPERIENCE

Sr. Industrial Engineer Oct 14 to Sep 17 ( 3 years ) Sonora, Mexico

IGB AUTOMOTIVE – Manufacture of high mix, low volume of heat and vent systems for automotive industry

• Management of multiple projects for more economical manufacturing methods & costs

• Plan and develop new production processes for New Business Introductions ( BMW, Audi, Tesla, VW 326)

• Responsible for the transition of new products from development into production

• Analyze blueprints and other documentation to prepare labor, material, tooling and equipment cost estimates

• Determine standards, production goals, rates, based on equipment and labor availability and workloads

• Performed time studies to determine the required number of headcount and machinery.

• Validate accuracy of Customer BOM’s, Drawings,

• Implement & propose part changes (ECN’s, change requests).

• Continuous improvement of existing process/products using Lean Six Sigma Tools 5S, Kaizen, TPM,

SMED, VSM, DMAIC, Poka Yoke to eliminate process wastes (big amount of WIP, batch processing,

unbalanced lines, long distance material flow ) and reduce process variation eliminating causes of defects.

• Review metrics/KPIs performance, to focus on top loss areas.

• Efficiency improvements through improved process work flows and equipment layout,

optimizing space requirements and assist with recommendations, justifications, installation & set-up

of new machinery/tools: Laminating Machine, RF Sealers, Self- feeder Soldering Stations.

• Identify Cost Reductions / value analysis for improvement of processes, products, and methods.

• Root causes analysis & implementation of long term effective corrective/ preventive actions.

• Analyze Data and Information (Minitab/ Excel Reports)

• Monitor Critical Processes; Capability Reports(Cpk, Ppk) and SPC Control Charts

• Prepare/Modify work instructions and process procedures.

• Audit & maintain up to date process data, plant layout, PFLOW charts/ PFMEA's, Control Plans.

• Design & modifications of tooling, fixtures and jigs on Auto CAD (2D).

• Determine machine settings for various equipment as Laminating machine, RF Sealers, Sonic Welding, Slitter

• Conduct training of operational and technician staff.

Selected contributions

• Labor cost reduced on final assembly from 112 to 80 associates through balance operations, cell manufacturing, one piece flow,

eliminated unnecessary inventory/operations (cut wires & tinning) $160K year savings

• Introduced new technologies (roll laminating, RF Sealers) 16 operators reduction; $80k/year savings & efficiency improved 30%

• Improved Plant Layout: 5400 sqft released ( 25.5 % of floor space); $11.4 K year savings and 335 feet eliminated on material travels.

• Reduced scrap by changing the design of Die Cuts & DSTs with YTD savings (35 weeks) $42.7K FY17.

• Quality Levels Improved: External PPMs maintained at 9 0n FY17 (36 weeks), FY16 YTD=21, FY15 YTD=25.

• Applied SMED in stitching machines changeover reduced from 10.35 to 3.76 minutes and output increased 11.7 K parts/week.

• Over 150 new parts successfully implemented for Audi, Tesla, BMW and VW 326 New Business.

Continuous Improvement Engineer Feb 14 to Sep 14 (8 months) Guanajuato, Mexico

NIFCO - Injection Molding Parts for Mazda, Honda, Nissan

• Participate on the starting up of this Japanese New Facility

• Responsible to implement Lean Manufacturing in the plant

• Facilitated KAIZEN events for focused problem solving and continuous improvement projects

• Lean Manufacturing Training on 5’s, SMED, TPM, Kaizen, Wastes, DMAIC, One Piece Flow

• Applied Lean concepts to reduce cycle times, WIP, Setups, Defects, Scrap, Rework, downtimes

• Performed GEMBA walks on a frequent basis to track production and tackle quality problems

• Work with quality to assure continuous improvement for defects found (Ishikawa, Pareto, Five why’s)

Contributions

• OEE Improved from 51% to 76% using SMED reducing molds change over on 75t~100t machines from 90 to 30 min

and 180t~350t machines from 150 to 45 minutes

• Labor cost reduced on molding area from 48 to 30 operators (savings $85K USD FY14 by unifying operations (molding & assembly)

Manufacturing Engineer Sep 10 - Jul 13 (2 years, 10 months) Sonora, Mexico

COMMERCIAL VEHICLE GROUP – High volume of electrical wire harnesses for heavy equipment markets

• Design & validate new over molding production line start up for Caterpillar D Serial Dozers New Business ( EAU:30K, $3M Sales)

• Review and select required special equipment & materials: Cannon Metering Machine, BASF Polyurethanes

• Define assembly methods, design reviews for new molds, set process parameters, lay out of equipment,

Work flow, capacity, training personnel, define tools, production parts approval (PPAP), run at rate studies

• Responsible to improve KPIs on the assigned areas of over molding, circuit boards assembly and electrical testing

• Yield improvements using 6 sigma/quality tools (fish bone analysis, SPC, Cpk, Ppk, GR&R and Poka Yokes)

Contributions:

• Cost Reduction Project: fabricate in house molds for prototypes using hard resin $120K total savings

• Quality improved on lines 8,9 and 14, internal ppm's reduced from 14K to 3K and external from 2K to 50 ppm's.

• Scrap reduced on lines 8,9, and over molding area on FY12 scrap cost reduced ~$14.5 K and FY13 ~$32 K

Business Unit Leader & Manufacturing Engineer Jan 03 - Jun 09 ( 6 years 5 months) Sonora, Mexico

Newell Window Furnishing - Decorative Industry

Business Unit Leader - Promotion ( 4 years 2 months)

• Responsible for the Operation Management of the sampling books business unit

• Direct and coordinate the activities of 120+ hourly employees and 6 salaried people

• Coordinate and plan for that production schedules met 100% in quality, quantity, cost and time.

• Create and manage KPIs for the operation

• Cost reductions: Re-use of remnants to fabricate sampling books project total savings of $180K dollars

• Output increased from 180 to 300 books daily

Manufacturing Engineer ( 2 years 3 months)

Participate on a team to move from push to a pull system as part of pilot program to develop Levolor Production System

• Plant layout converting lines into balanced U- Cells. Layout used to hold 13 Lines, changed to 18 cells in same space

• Make recommendations to improve product designs for new cordless blinds for manufacturability

• Scrap rate per blind decreased 22%; target in 2003 $1.49/blind and achieving $1.16/blind

NPI Engineer Oct 01 - Jan 03 ( 1 year 3 months) Sonora, Mexico

Miniature Precision Components - Extruding tubing for evaporative emissions systems for Automotive Industry

• Develop the new manufacturing processes for product introductions and transfers

Process Engineer Jan 01 – Sep 01 ( 8 months) Sonora, Mexico

COORSTEK– High Precision Machining of ceramic parts (tight tolerances)

• Responsible to transfer, validate and document the production lines from USA to Mexico new facility in Mexico

• Scrap level Improved: In Golden USA Scrap levels 10%, reduced to 2 % in Mexico

Manufacturing Process Engineer Oct 97 - Jul 00 ( 2 years 9 months) Sonora, Mexico

ADFlex Solutions - Electronic Industry. High volume production +1500 employees operation

• Clean room upgrades from class 100K to class 10K for flex electronic circuits

• Introduced new technologies to reduce defects/costs (de-ionizers, tacky rollers, circuit washers)

• Equipment modifications: PPMs reduced in +25% due to Inline cleaning process development,

EDUCATION

BS, Mechanical Engineering

Universidad Autonoma Chapingo

TRAINING / COURSES

Six Sigma Green Belt Training by CVG,

Kaizen tools and 7 Wastes Training Course

Course on Statistical Thinking for Manufacturing Process Control by American Supplier Institute of Mexico

Machine / Process Capability Study “Six Sigma Projects” by “Advance System Consultants”- Motorola, Phoenix Az.

SKILLS

- Experience using Minitab, AutoCAD (2D), Statistical Process Control (SPC), Excel/ Data Analysis, Ms Project, Oracle, SAP, X-pert

Contact this candidate