Manager Manufacturing

Rogério Silva de Carvalho

Brazilian, married, ** years old.

Rua Luis Sergio Sepini, 220

Parque Urupês – Varginha – MG

Phone: (55-35-998****** ou (35) 3212 7422. E-mail: *********@*****.***.**

OBJECTIVE

Process Engineering/ Lean Manufacturing/ Project Management

EDUCATION

Graduate Education: Industrial Metallurgical Engineering – UFF-RJ (1989).

MBA – FGV . Missing 04 class to finish.

Language: Fluent English, Advanced Italian and Basic Spanish.

PROFESSIONAL WORK EXPERIENCE

Cooper Standard Automotive - Brazil. Sealing and Fluid Systems Manufacturer, 1500 employees.

Position: Advanced Process Engineering Manager Period: 08/2014 - 09/2015.

- Managed Engineering duties at Extrusion operations EPDM and Thermoplastic TPO/TPE, as well as Die shop-Tooling Manufacturing and Material Development.

- Managed all process development and modifications to PSA, Honda, Toyota projects, prototyping, manufacturing and monitoring machines, following the assembly of parts for validation of processes and products as TS16949 standards, procedures and requirements of the customer until ramp up phase.

- Provided Engineering support to new product team to ensure that all products introduced into manufacturing meet product and process quality criteria defined by customers.

- Checked schedule applying MS Project taking actions to ensure the deadlines agreed with the client.

- Established the design review and project review to meet the goals of implementation of new programs and processes. Promote audits and meetings of decision-making of the Project.

- Managed and ensured the deployment of new tools for continuous improvement (VSM, KAIZEN, SPC, TPM, SMED, 5S) achieving 6% cost reduction over sales.

-Defined specifications, selected suppliers and supervision the timely implementation of process, tooling and equipment according customer expectations.

- Developed, implemented and maintained an aggressive focused approach to product testing and process/product, quality measurement.

- Coaching the team on problem solving applying PDCA, Minitab and 6Sigma tools for all process to find RCCA to reduce downtime and scrap.

- Supported QSB with participation on Fast Response, 8D report, PFMEA, Poka-Yoke, Lessons Learned, Standard Job and Audits.

- Quality System member reviewing and updating the ISO procedures of Extrusion Process and Die shop.

- Ensured safety of personal, goods and compliance to CSA environmental policies.

- Participated on weekly base of Technical Worldwide Conference about Process standardization.

- Technically supported the commercial team during RFQ and CAPEX assessment.

- Drove performance improvement and tooling maintenance on Die Shop area.

- Improved Die life usage control and created back up Die for top10 High volume profiles.

Hutchinson Automotive - China. Sealing and Fluid Systems Manufacturer, 1200 employees.

Position: Industrialization and Process Engineering Manager. Period: 06/2012 - 05/ 2014.

- Managed Manufacturing Engineering duties at Extrusion Lines (EPDM and Thermoplastic TPO/TPE ) and Finishing operations (Cutting, Molding, Assembly, Gluing, Printing, Packaging), as well as Tooling Manufacturing and Materials Development.

- Coordinated in terms of cost, quality and timing, the production launch of new projects according internal and external customer’s procedures. Projects developed: Ford (C520, CD391), Volvo (L421), JLR (L538) using pull system concept. Since the flowchart definition, Equipment’s definition, Lay out, Control Plan, Work Instructions, industrialization phase and ramp up for SOP.

- Selected, validated and coordinated the implementation of optimized material specifications.

- Coached the team directly and indirectly on problem solving applying Minitab and Six Sigma tools for extrusion and finishing process to proceed troubleshooting and route cause analysis.

- Worked with the Purchasing Team on supplier development activities for new programs.

- Elaborated and control the CAPEX and cost accounting.

- Managed spending against budget, control spending in relation to manufacturing.

- Trained/developed local team and specifically supervision and management to support transition of responsibilities to the local team.

- Drove OEE Process Improvements at extrusion and finishing process.

- Actively participated on elaboration and implementation of quality problem solving activities.

- Managed and ensured the deployment of Lean methodologies (KAIZEN, MTM, TPM, SMED, 5S).

Cooper Standard - South Korea. Sealing and Fluid Systems Manufacturer, 750 employees.

Position: Manufacturing & Continuous Improvement Manager Period: 05/2010 - 05/2012.

- Managed Manufacturing Engineering duties at Extrusion Lines (EPDM, Thermoplastic TPO/TPE) and Finishing operations, as well as Tooling Manufacturing and Materials Development.

- Provided Engineering support to new product to ensure that all products introduced into manufacturing meet product and process quality criteria defined by customers and organization goals.

- Looked for Process improvement the overall performance using DMAIC 6Sigma, VSM, Kaizen, 5S, TPM.

- Actively participated on elaboration and implementation of quality problem solving and analyze activities applying troubleshoot in process supporting Production, Maintenance, Logistic teams.

- Solved manufacturing problems related to equipment, processes, or designs implementing sistemic actions.

- Dialy followed production processes and made several changes for improvement; applying best practices to insure cost reduction, lower scrap rate, high process quality assisting also ergonomic and safety workplace.

Cooper Standard - Brazil. Sealing and Fluid Systems Manufacturer, 1200 employees.

Position: Project/Program Manager and Process Engineer SR. Period: 06/1999 - 04/2010.

- Made the Project management of the development and modifications for Fiat, Iveco, MBB and Pilkington, operating from Co-design project, prototyping, manufacturing and monitoring machines, following the assembly of parts for processes and products validation with prototype and final tooling as TS16949 standards, procedures and requirements of the customer.

- Follow-up schedule with MS Project, taking actions to ensure the deadlines agreed with the client.

- Establish the interface between the sectors, meetings of advancement of the project, to meet the goals of implementation of new programs and processes. Promote the interface between customer and internal sectors of audits and meetings of decision-making of the project, promoting the necessary negotiations.

- I received the prize" Fiat Qualitas-2006 "for outstanding product development among suppliers to Fiat Punto platform.

- Advise management guidelines using Lean 6Sigma tools to develop new products, seeking opportunities to reduce cost and increase profit margin. (Gap Analysis).

- Responsible for the development of the entire production process, machinery, tools, sizing of manpower, and analysis of time in the extrusion lines for new projects.

- Elaborate process flow and management of DFMEA / PFMEA.

Mangels Indústria Ltda. Manufacturer of alloy wheels, LPG containers, Air Tanks and Fuel, 2300 employees.

Position: Production Supervisor Period: 09/1994 - 05/1999.

- Managed production, logistics, materials, maintenance, technical assistance and contact with all clients.

Companhia Siderúrgica Paulista – Cosipa. Steel Plant. 17.000 employees.

Position: Process Development Engineer at Hot Strip Mill Line Period: 03/1990 - 08/1994.

TRAINING

QSB+ GM/PSA - INTERACTION PLEXUS

6-Sigma/ Advanced Statistics - CSA

Black Belt em 6Sigma Training-QPB / Buchaim

DOE-Design of Experiments – CSA

VSM – Lean Institute

Técnicas de KANBAN – STRAIGHT

Lean Manufacturing (Kaizen / Kanban) – CSA

APQP Gerencial – I PLEXUS

Lean Manufacturing (Fast Setup) - Lean Institute

MS Project - BESSA Consultores

5S application - CSA

8D Global – Ford/QPB

Quality Auditor - TS 16949 - LANNES HOFMAN

SAP – CSA

System QS9000, ISO14000, TS16949 - CSA

FMEA-4 ª Ed - INTERACTION PLEXUS

Process Auditor training VDA 6.3 - QUALITAS

Solid-Works – CSA

INTERNATIONAL EXPERIENCE

.Wuhan / China - Expat Contract (02 years) (Jun 2012 to May 2014)

.Gunsan / South Korea - Expat Contract (02 years) (May 2010 to May 2012)

.Vitré/ France - Fiat 327 Program Launch - Development Codesign. (2009, Jul)

.Torino/ Italy - Fiat 326 Program Launch - Development Codesign. (2008, Jul to Dec)

.Torino-Batipaglia/Itália - Fiat BRAVO Program Launch – Visit Metzeler Plant. (2008, Mar)

.Torino/ Italy Fiat LINEA/ PUNTO Program Launch - Visit Fiat Plant (2007, Fev)

. Monitoring of test performance (Wind Gallery / Water infiltration) and qualification.

. Gliwice/ Poland - Visit GM plant. Follow assembly of parts in the production line. (2008, Jun)

. Turkey LINEA/ PUNTO Program Launch - Visit Fiat Plant. (2007 Jan, Mar,Jun,Dec) e (2008, Jun,Aug, Oct).

. Technical and preconization assembly of parts in the production line.

. Monitoring the assembly parts in Master and Pre-Series to product approval.

. Buenos Aires/ Argentina- VW Plant.Technical Assistance for Space Fox. (2007, Nov)

. Maesteg/ UK– VW POLO Program Launch - Technology Exchange CSA. (2001, Mai)

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