Manager Quality

Luis Alberto Monroy Rojo

Piedras Negras, Coahuila. Cell 011-**-*-***-*** 0431

SUMMARY OF QUALIFICATIONS

• Industrial engineer with 15+ years of experience managing engineering, launch, quality and manufacturing for

operations in Mexico, US and Canada.

• Experienced on launch projects, tracking of tasks on time, perfect communication all across the board on the

organization, leadership on launch activities throughout the company

• Skilled in the implementation of quality systems to include TS 16949 and the application of quality tools FMEA,

Control plan, PFD, PPAP documentation, APQP, 8D’S, JIT, SMED, POKA YOKE, QFD, KANBAN, DOE and

GD&T.

• Experienced on development and implementation of effective process control systems, measurement systems and

quality metrics with a solid track record of improvements and cost saving projects

• Key training and technical proficiency in AutoCAD, project, PPAP, software, ORACLE, Minitab and MS Office.

• Trilingual English (95%), Spanish (Native language), and Italian (40%)

• Excellent top management interaction within corporate and customers, such as VPs, Presidents and Directors

with executive reports to top management experience

PROFESSIONAL EXPERIENCE

General Cable - Piedras Negras, Coah

Global leader in the development, design, manufacture, marketing and distribution of aluminum, copper and fiber optic

wire and cable products for several markets

Acting Plant Manager Nov 2014 – Present

• Full P & L responsibility for overall growth and profitability for Piedras operations with direct interaction to the

sales group and customers

Engineering/Quality Manager: Apr 2014 – Present

• Responsible for the customer satisfaction and internal change of mind process to quality culture as well as the NPI

process at the plant

• Support HH team to develop a new process for ECNs and NPIs in order to eliminate time process at plant level to

support production floor activities

• Administrate engineering and quality goals to achieve results thru training and coaching

• Strict follow up to customer rejections (CCPs) in order to implement a 48hrs response culture

• Break paradigms thru the engineering and quality teams

• Interaction on purchasing, bids and contracts

Key Achievements:

• Zero CARs and observations on IRIS Audit

• Reduction of quality cost from 118K USD to 3K USD during the last 6 months

• Reduction on customer rejection closure thru 8D from 95 days to 8 days

• Reduction on customer rejections from 47 open in average to 10 open in average on Monthly basis

• Reduction of 40% on daily timing from Engineering by balancing tasks with HH team

• Introduction of Production Supervisors reporting quality issues with 8D methodology

• Increase prototype from 79% to 88.6%, NPI from 49.5% to 87.1% and ECN quoting from 67% to 96.1%

• Responsible for changing the paradigm on current thinking

• Elimination of final inspection bringing quality at the source

Lear SSD/Metals and mechanical division - Piedras Negras, Coah 6.1 years

Leading global supplier of automotive seating systems and electrical power management systems

Launch Manager: Jul 2012 – Apr 2014

• Responsible for all Lear Piedras Negras Campus (4 plants), with over 15 current launches for the next 15 months and 3

mayor transfers between Lear Plants

• Leading one of the most important projects at NA division, EVO tracks (Alpha, K2XX, GSV, 31XX, A1BC,Lamborghini

and Maserati) among others for BMW and Mercedes

• Manage the transfer of lines to other Lear facilities across Mexico and USA, Leading meetings and transfer plan

• Support engineering to create spaces for new projects as K2XX for GM and CUSW for KL

• Manage launch budget on monthly basis with the core team to ensure a flawless and correct launch

• Continuous communication with HQs and Top management thru executive reports

• Responsible to determine manufacturing feasibility of processes determined by design

• Responsible to do mounting charts to calculate demand vs capacity to foresee any impacts

• Responsible to ensure the quality of pre-production phase with PPSRs and traceability methods

Key Achievements:

• Zero incidents nor accidents during launch phase (6 Months after SOP)

• Zero quality spills during launch phase

• Total attainment to budget

• Flawless launches during the phase of maturing

Engineering Manager: Apr 2011 – Jul 2012

• Administrated and coached engineering group for the 4 facilities at Piedras Negras (17 engineers)

• Followed up on VAVE’s and cost savings from an engineering standpoint with over 70k dollars on a year basis

• Acted as core team member of the launch team with 6 projects for 2012, leading one of them as project manager

• Controlled department’s budget

• Coached engineering changes thru the plant with product engineer support, merging lines to create flexibility at

production in order to run different products instead of dedicated lines

Key Achievements:

• Rebalanced processes throughout the plant with MOST study obtaining a labor optimization of 57 heads 2011

• Led the APQP paperwork related to engineering such as PFMEA, flow diagrams, set up sheets and critical

characteristic list, continuous improvements to the process on layouts thru the plant with over 7 mayor equipment

changes giving benefits on material flow, quality items, productivity and efficiency

• Led A-Coat paint process improvements at 35% over the last semester of 2011 based on Henkel audit, adding IEX unit

to obtain 15K USD per month on savings due to decant reduction at 90%,

Manufacturing Manager: Aug 2010 – Apr 2011

• Implemented a playbook to follow on the production floor to establish discipline

• Coached supervisors to eliminate constrains at the floor and break paradigms of manufacturing

• Added BSC at the staff level to link the strategy throughout the plant

• Promoted participation on the Champion program for new launches at the plant

Key Achievements:

• Introduced responding to the customer from the root system, by making the supervisors an agent to the customer on

quality issues

• Increased productivity from 50% to 85% at BMW product

• Reduced over time with scheduled attainment

Quality Manager: Sep 2008 – Aug 2010

Key Achievements:

• Contributed to the elimination of containment at customers from 50,000 monthly on average to 0k

• Excellent customer service and relationship

• Reduced the formal concerns of customers from 12 monthly to 1 every other month by leading process walks, read

across lines, RFMEA's and follow up to lessons learned

• Reduced scrap from 15% to 5% vs. sales

• Achieved savings of up to $150K USDs. for welding project

• 3 main launches on 2008 with no defects

• Achieved Q1 status at Lear Piedras Negras and 0 non conformances or observations at TS recertification audit on 2010

• Active member of the bell to bell program, knowledge of sampling plans, inspection criteria and techniques, critical

attributes, process validations, statistical methods, disposition of non-conforming product and trending methods

Corporate Quality Manager (Juarez): Jan 2008 – Sep 2008

• Responsible for the overall quality at the Mexico Metal-Mechanic and welding plants which included Monclova, Tlahuac

and Piedras Negras plant

• Worked directly with customers on quality issues

Key Achievements:

• Implemented countermeasures effectiveness verifications at the production floor

• Implemented systems and procedures to eliminate potential incidents

• Worked with methodologies such as 7 diamonds and Red X (Shainin) among others

• Champion of the quality hero project designated to recognize the value of the associates focusing on quality, metals

team best practices and Poka Yoke pieces to eliminate scrap and poor quality costs

Fanosa – Cd. Juarez, Chih. 3 Years

Company dedicated to the production of expanded polystyrene products in Northwestern Mexico.

Operations Manager: 2005 – 2008

• Coached departments such as Production, Quality, Maintenance, Warehouse/Logistics, Manufacturing, purchasing and

interacted with Finance and Human Resources

Key Achievements:

• Implemented Lean Manufacturing principles such as waste elimination, one piece flow, 5’s, Kaizen and Kanban

• Obtained cost reductions of over $500K in 2005 and $150K in 2006 through variability reduction and waste elimination

• Increased productivity from 65% to 80% through implementation of OEE

• Achieved a 95% uptime on production floor machines through implementation of TPM

• Scrap reduction from 22% in 2005 to 15.5% in 2006 on finished goods (lowest rate for the polystyrene industry due the

hot wire cutting is 12%)

• Increased delivery rates from 89% in 2005 to 99.7%

• Launched program with over 25 improvements in 2005 and over 65 in 2006

• Eliminated the final inspection through “the quality on the source” program, dropping the customer rejects from

15KPPM to 1,4KPPM and the internal reject to nearly zero

• Implemented the multi-skilled program with cross training, reduced over time in 97.65% from 2005 to 2006

• Worked on R&D with manufacturing and maintenance teams to reduce cycle time from 7 minutes to 2 minutes

• Followed up on metrics through BSC (Balance Score Card) keeping metrics of the plant in outstanding levels according

to the corporate and market rates

• Improved operations dramatically, turnaround from negative numbers in 2005 to profit of over 1 million dollars in 2006

Sensus Precision Die Casting - Cd. Juarez Chih. /Russellville KY

Manufacturer of aluminum components for a wide range of markets, including automotive, meters, small engines, and

electronics industries.

Regional Manager: 2002 – 2005

• Responsible for the Sensus Precision Die Casting Automotive Division performance with customers in Mexico such as

Visteon (Ford supplier) and Delphi Queretaro (GM supplier)

• In charge of new product launches and APQP

• Supervised containment actions, 8D’s, logistics and warehousing

• Followed up on quality issues improvement plans and provided fast response to the customer

• Avon Automotive - Cd. Juarez Chih.) 4 years

The company develops material and design solutions for automotive applications in the areas of Fuel, Air Hose, and

Coolant.

PPAP & APQP Engineer: 2000 – 2002

• Supervised and managed the Product Engineers Team (6)

• Transferred 20 products from Orizaba to Juarez facility

• Led FMEA, Control plan, PFD, PPAP documentation, APQP and contact with suppliers and customers

Key Achievements:

• Implemented samples audit in order to have defect free products and the feasibility meetings

• Reduced lead time of samples from 17 to 8 days (47%)

• Applied GD&T, customer standard, at charge of the customer samples, Manufacturing flow, design and cost analysis

for the prototypes area

Prototypes Engineer: 2000

• Kept direct contact with customer for their requirements

• Actively collaborated on try outs for Ford and prototype runs with Chrysler

Key Achievements:

• Increased the performance of prototypes from 38% to 98% in three months and improved the prototypes area with 5’s

• Introduced the utilization of board assemblies for the prototypes

Customer Quality Liaison: 1999 – 2000

• Acted as liaison between company and OEM customers on quality issues and continuous service for the potential

solutions on the 8 disciplines to solve customer concerns

• Implemented methods to find out root cause such as fish bones, 5W 1H, brainstorming and DOE

• Implemented Poka Yokes to eliminate defects, more than 40 8D’s closed with customers satisfied

Lear Corporation - Hermosillo, Son. 2 Years

Quality Specialist and QS9000 Key Sponsor: 1997 – 1999

• Applied 8D’S, PPAPS, FMEAS, APQP, JIT, SMED, POKA YOKE, QFD, KANBAN, DOE, and 21kaizens in one year

and active member on Kaizen program

• Liaison between quality department and suppliers

Key Achievements:

• Developed the foam spray project

• Implemented a better way to make the QS9000 internal audits

EDUCATION

BS in Industrial Engineering (1998) Instituto Tecnologico de Hermosillo

Additional professional development includes:

• Lean Technician April 2014 – In house

• MSA & SPC April 2014 – Quality House

• Project Management Jun 2013 – University of Wisconsin at Madison

• Leadership “The power of change”, Apr 2013 - GRID

• APQP, 2ND ED, PPAP, 4TH ED, Apr 2013- Lancastec

• MOST Technique Certification Course, Apr 2012 - Accenture Rochester Hills

• Lean Manufacturing Course - Lean on us/ITCJ Ciudad Juarez, Chihuahua

• Laser Beam, Diagnostic and Tools Course, Oct 11 - University of Wisconsin at Madison

• 7 Habits of Highly Effective People Course - Lear Corporation, Piedras Negras, Coahuila

• 7 DIAMONDS Methodology Course - Lear Corporation, Ciudad Juarez, Chihuahua

• Leadership, Communication, Productivity and Quality Course - ITESM Campus Ciudad Juarez

• Problem Reporting & Resolution (PR&R) Course - Delphi headquarters, Troy Michigan

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