Joe Chavez

***** ****** ***** * *******, CA ***** n 909-***-**** n Email: acugy4@r.postjobfree.com

Qualifications Summary

Senior Level Operation Manager

** ***** ********** ********** **** Established Companies/Start Up Ventures/Turnarounds.

Participative management professional: results focused, entrepreneurial and practical. Progressive leadership experiences have created a passion for surpassing financial and other corporate objectives via a combination of world class service and delivery, Lean operating methods, and incentive driven rewards for team achievement. Derive pleasure from transforming high potential staff into outstanding leaders demonstrating the creativity critical to financial and operational success.

Proven Expertise

Operations Management

Lean Manufacturing

Design for Manufacturability

Inventory Control

P&L Management

Strategic Planning

Six Sigma

Cost Controls / Scrap Reduction

Cost Reduction/Containment

Team Building and Staff Retention

Professional Experience

Argyle Security (Orange, CA)

$150 million global manufacturer of Detention Equipment

VP of Operations, July 2012 to March 2016

Reorganized company and stopped 32 consecutive months of loses within three months. Turn around complete with profits of $1.1 million vs $1.2 million in losses annually for five years.

At PDI division, introduced Lean and created new plant layout from Value Stream Mapping activities…reduced manpower from 54 employees to 26 while maintaining revenues.

Kaizens and Kanbans created to manage inventory and reduce lead times from 12 weeks to 4 weeks.

Southern Folger Detention Equipment Co (San Antonio, TX)

$60 million global manufacturer of Detention Equipment

Director of Operations, 2007 to 2012

Reduced lead times from 18 weeks to 8 weeks, reduced manpower by 38% and improved EBITDA from 11% to 23%.

Reduced WIP and total Inventories by over 50% from $7.8 million to $3.8 million. Introduced Kanbans internally and with suppliers.

Implemented Lean Manufacturing and created Cell Teams in Lock Assy reducing manpower from 42 to 17 employees…saving the company $1.1 million/year.

A&A Fabrication (Whittier, CA)

Custom manufacturer of precision fixtures for Aerospace Industry

Partner/Owner, 2006 to 2007

Led company in obtaining ISO certification and secured contracts with Bombardier and Boeing.

Grew company from $1.2 million to $4.5 million and created Cell Team using Lean principles.

Inventory turns of 22 using Kanbans and JIT methodologies.

La-Z-Boy (Redlands, CA)

$2.8 Billion -Manufacturer of upholstered recliners and sofas

Continuous Improvement Director, 2005 to 2006

Created new factory layout, removed all process specific departments and collapsed all work into Cells. Efficiencies and Productive improved by 35%.

Changed compensation from piece part to team pay for each Cell…decreased turnover from 25% to less than 10%. Pay increased by an average of 16% working in Cell Teams.

Saved 28,000 jobs company wide by not outsourcing to China while improving EBITDA by 6% in first year.

Jacuzzi Brands (Chino Hills, CA)

$1.6 Billion -Manufacturer of Spas and Whirlpool baths

Plant Superintendent, 2004 to 2005

Reduced lead time from 24 days to 4 days by streamlining operations and removing constraints in thermoforming, fiberglass, and drilling.

Reconfigured 560,000-square-foot plant layout, which improved worker efficiency, reduced material waste by 28% and reclaimed 225,000 square feet of space.

Eliminated $12,000,000 in Inventory by changing to make-to-order instead of make-to-stock.

Reduced manpower by 24% by eliminating rework, reducing scrap by 88% and retraining of temporary employees. Saved 3,800 jobs from not outsourcing to Mexico by improving all corporate mandated metrics.

HeadWest (Compton, CA)

Custom manufacturer mirrors for retail

Lean Consultant, 2003 to 2204

Created Pull System to improve lead time from 3 weeks to 3 days to comply with Home Depot and Lowes scheduling and on time requirements.

CEH (Santa Ana, CA)

Custom manufacturer of precision fabricated enclosures

VP of Operations, 2002 to 2003

Streamlined process for fabrication of stainless Steel BBQ grills for two major contractors…reduced cost by 35% to meet demands by customer and avoid sending work to China.

Swift-Cor (Gardena, CA)

Custom manufacturer of precision fabricated enclosures and Aerospace subcontractor to Boeing

Director Operations, 1996 to 2002

Reduced WIP and total Inventory by over 50% from $8.8 million to $4.1 million.

Created JIT process for Compaq Computers projects…Kanbans saved 35% in labor cost, $2.2 million/year

Implemented Lean Manufacturing and raised EBITDA from 4.5% to 16%.

ISO Enclosures (Fontana, CA)

Custom manufacturer of slot machines

Owner, 1994 to 1996

Manufactured slot machines for Indian Gaming industry…first to introduce large 19” monitor screens, bill validators and receipt printouts rather than coin hoppers and push button controls rather than handle.

Premier Metals (Fontana, CA)

Custom manufacturer of fabricated metal products

Director Operations, 1990 to 1994

Led two new product introductions, one for lottery dispensing machines and other for Vegas style Slot Machines, handling all phases of manufacturing from concept through production launch.

Implemented Lean Manufacturing and improved IBITDA from 7% to 18%.

Value Stream reorganization of all process areas to eliminate waste.

Wyle Labs (El Segundo, CA)

Manufacturer of enclosures for Aerospace, DOE and DOD

Engineering Manager, 1982 to 1990

Led team of 15 Engineers and 5 Programmers on projects for TRW, Lockheed, Hughes Aircraft, Martin Marietta, Ford Aerospace, Loral Data, Northrop Grumman and many other government contractors.

Lean training with consultants and UCLA extension courses.

Design and manufacturing of special projects for several military programs like Patriot and Cruise missiles, FA18, B1, Space Shuttle and others.

Education

Manufacturing Eng Coursework, 1979 to 1981 CAL STATE L.A. (Los Angeles, CA)

Operations Management, 1989 UCLA EXECUTIVE PROGRAM (Los Angeles, CA)

Toyota Production System, 1990 to 2004 TCA and other consulting groups

Six Sigma Black Belt, 1999 GE Financial Services Executive Training

Highlights: Kaizen and Rapid Deployment Projects at Boeing’s Facility

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