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Manufacturing Engineer - Lean Manufacturing

Location:
Toronto, Ontario, Canada
Salary:
85-120K a year
Posted:
October 19, 2016

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Resume:

JOSE A. CASTILLO

*** ********* **. *******, ** M*E 4T4

E-mail: acw49z@r.postjobfree.com

Home Phone: 647-***-**** Cell Phone: 647-***-****

Plant Manager

Over 10 years of manufacturing processes and industrial engineering experience, focusing on Automotive Parts production, Sheet Metal Fabrication/Welding processes and Electronics Manufacturing

Trained in LEAN Manufacturing, Continuous Improvement Implementation, SPC and 5S. Delivered double-digit gains in direct efficiency & productivity.

Specialized in the implementation of welding processes in manufacturing and assembly

Creative problem solver, highly experienced with new Process Planning, Execution, Budgeting, Training and Resources Allocation & Determination.

Above average organizational skills. Strong analytical, problem solving and decision-making skills.

Experienced managing operations and engineering staff including leading and directing the workforce and establishing Work Schedules and Procedures.

Excellent communication, interpersonal and leadership skills.

Self-starter, driven, flexible, motivated and results oriented.

Excellent Proficiency in Spanish, written and verbal (native speaker)

Open to international opportunities. Willing to relocate & travel if required.

PROFESSIONAL EXPERIENCE

Wilson Tool Canada in Toronto

Head Office Located in White Bear Lake, Minnesota

Business Unit Leader Oct 2015 - present

Manage all aspects of Dies Fabrication and provide technical support for Punches Fabrication.

Supervision and delegate activities related to Production personnel

Lean Manufacturing Activities: currently working on 7 waste elimination projects for Continuous Improvement objectives.

Responsible for the redesign of the Manufacturing Process Flow for Punches and Dies

Perform Demand Analysis for new Facility, implementing proper Manufacturing Process Flow layouts in the new facility

Provide Safe Inventory Determination for existing customer demands for Punches and Dies

Provide Process Cross-training Development to new and existing staff: ensuring better and consistent achievements of production for customer requirements

Greater Toronto Airport Authority

Security Agent

Contract position non-related to manufacturing Aug 2014 - Oct 2015

National Concrete Accessories

Process Engineer - Contract Position Jul 2013 - Jul 2014

Canada

Key Contributions:

Improved machine utilization by 2% and OEE by 5%.

Performed an Engineering Work Study to determine top offenders (issues) for overall machinery and equipment in the plant.

Tracked key equipment production according to the production target and helped operators to achieve their productivity goals by providing technical support and applying engineering principles.

Conducted and led activities to set up and improve on efficiencies and productivity benchmarks

Developed Process Flow Charts, Cause and Effect Analysis, PFMEA to reduce severe failures and their effects in conjunction with input from other team-members & machine operators.

MJ Manufacturing (a Division of Martinrea )

Project Engineer (Project Mgr. Assistant) - Contract Position Jul 2012-Jul 2013

Canada

Key Contributions:

Supported and directed the transfer of the production module from Toronto, Canada to Mexico for the Thermo-King ICON Frame Project involving Robotic and manual MIG welding equipment

Supervised and followed up on the implemented APQP System for the span of the 1 year contract.

Coordinated all process development and equipment sample runs at both vendor and in-house locations

Conducted Conference Calls to support / track communication and Project Development Issues.

Documented relevant information into APQP, PPAP and Control Plans for Corporate and Management reviews.

Developed Process Flow Chart, Capability Studies, DOE's, DFMEA, PFMEA reducing severe failures and their effects in conjunction with input from other team members.

Flextronics Manufacturing Feb 2010 - May 2012

Manufacturing Engineer II (Immigrated to Canada)

Canada & Mexico

Key Contributions:

Managed the first phase of Robot MIG Welding Process from quotation to installation to produce hospital bed frames, transferring business from Quebec, Canada to Mexico and implementing up to three (3) Robot MIG Welding Cells.

Determined hand tooling, spare parts inventory and PPE for eight (8) Robot MIG Welding Cells.

Developed all program documentation including MVP, IQ, OQ and PQ Welding Validations and implemented continuous improvement, balancing the Robot MIG Welding Cells, increasing the production rate from 25 to 50 bed kits daily.

Utilized the experience and expertise of cross-functional team members to ensure equipment meets all cost, quality, reliability and productivity requirements.

Supervised "in process" products manufacturing and a team of 50 direct employees.

Led and directed the workforce establishing Work Schedules and Procedures.

Obtained quotations, compiled all required documentation, presented recommendations to the New Business Development Director and generated the corresponding purchase requisition for final approval.

Procured estimates for equipment, processes costs and raw material required.

Liaised with vendors and monitored progress through quotation, design, build and installation stages of all new equipment necessary for the new program, and ensured equipment modifications per engineering change requirements.

Involved in the implementation and maintenance of 5S standards within the workplace.

Fileco (a Teknion Company) Oct 2007 - Dec 2009

Maintenance Mechanic (Work Permit expired)

Canada

Key Contributions:

Performed preventative and predictive maintenance tasks and developed programs to reduce production time loss up to 20% in 2008.

Performed corrective maintenance tasks to reduce down time 5% in 2009.

Arizona Precision Sheet Metal (APSM/JIT) Apr.2005 - Dec. 2006

Manufacturing Engineer II (Personal Decision)

USA & Mexico

Key Contributions:

Trained 15 new workers certifying them as welders after having received MIG/TIG welding and robot programming training in Phoenix, AZ.

Opened a new factory in Mexico from Phoenix, AZ. in USA and implemented start and follow up of sheet metal massive production.

Implemented and recommended PLC's Robotic and Assembly Systems for Operational automation.

Recommended efficient machinery combinations resulting in increased direct efficiency by 40%, systematically balancing processes and applying bottleneck administration.

Performed PPAP, APQP, SPC & FMEA activities and applied in depth knowledge of Quality Engineering concepts and related tools such as 7 Tools, Drafting and Blue Print Reading.

Supervised a team of technicians, engineers, technologists, analysts and administrative staff with the purpose of reducing up to 5% of the total product cost, while increasing productivity and improving direct efficiency by 10%.

Mahle Motor Components in Mexico Oct. 1999 - Apr. 2005

Industrial Engineer (Laid-off)

USA & Mexico

Key Contributions:

Lean Manufacturing Leader - Implemented Delphi Piston Rings Lean Manufacturing System - analysed costs of production; designed, developed and conducted time studies and work simplification programs.

Developed CPK, SPC, work studies and technical procedures and obtained approval for specialized piston rings production.

Determined skill requirements and developed trainings programs.

Developed performance standards, evaluation systems and wage and incentive programs.

Performed activities as an Internal Auditor of ISO-9001, ISO-14001, ISO-18001, TS-16949.

Migrated business transferring machinery from US and Mexico City to another State in Mexico.

Industria de Asiento Superior Dec. 1992 - Oct. 1999

Industrial Engineer (Personal Decision)

Japan & Mexico

Key Contributions:

Implemented Layout, KAIZEN, 5S, MRP and PDCA (Plan, Do, Check, Action Car Seats Manufacturing System) improving the productivity of the Company continuously.

Evaluated operations, processes, equipment, staff and production capacity resulting in implemented continuous improvements in standard time, process and material flow, personnel reductions and lay out design.

Implemented TQC, SPC and developed technical procedures and obtained approval for NISSAN & HONDA Car Seats Production.

EDUCATION

Bachelor Degree in INDUSTRIAL ENGINEERING, MEXICO, 1994

Professional Engineering Ontario: PEO File # 100187565 ( in progress )

TRAINING AND QUALIFICATIONS

Supervision Health and Safety Awareness in 5 steps, CANADA, 2014

WHMIS, MSDS & Fall Protection Training, CANADA, 2007 & 2012

APQP & PPAP Training, MEXICO 2000 & CANADA, 2012

MVP,IQ,OQ,PQ-Installations,Operational & Performance Qualifications, MEXICO, 2011

Lean Manufacturing Training VSM, JIT, 8D, 3M's Training, MEXICO, 2000 & 2011

KAIZEN, 5"s", PFMEA, Pokayoke,TPM & SPC Training, MEXICO, 2011 & JAPAN, 1993

French Language - Beginner, Central Technical School, CANADA, 2009

AUTOCAD LT 2009 Yorkdale Adult Learning Centre, CANADA, 2008

Basic Spill Response, CANADA, 2008

Off Slab Scissor Lift Training, CANADA, 2008

SPC-Quality Assurance & Control American Society for Quality (ASQ), CANADA, 2007

Standard First Aid w CPR Level A - 2006 Protocols, CANADA, 2007

Working in Confined Spaces Rescue Level, CANADA, 2007

Lockout/ Tag out Training, CANADA, 2007

MOTOMAN / PANASONIC Robots Programming Training, JAPAN, 1992 & USA, 2006

PUSH & PULL Systems & Differences/ KANBAN Training, MEXICO, 2004

ISO-14001, ISO-18001 & TS16949 Internal Auditor Training, MEXICO, 2004

SMED Training, MEXICO, 2003

ISO-9001 Internal Auditor Training, MEXICO, 2003

SPC Training, MEXICO, 2002



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