Manufacturing Engineering Continuous Improvement
Resume:
Roberto Villegas
********.**@******.***
Greensboro, NC 27455
Objectives
To merge one’s own acquired knowledge and experience with a flourishing company aiming to achieve complete success through teamwork, innovation, and customer satisfaction.
Education
Nogales High School
1990-1991 Diploma
University of Arizona
1991-1994 Electrical Engineering Curriculum
University of Phoenix
2012-2014 Business Management Curriculum
Experience
Continuous Improvement Specialist 2023 – 2024
ZIM Aircraft Cabin Solutions – Greensboro
ZACS 8010 Piedmont Triad Parkway Greensboro, NC
Introduced standardized current and future state mapping to capture the current condition of struggling processes and its pain points to develop a stable future state
Updated standard operation procedures as necessary to document future state and bake new processes into the departmental standard work and control plans
Worked closely with the IT department to develop Power Bi dashboards and reports that aligned to future state processes and procedures to gain efficiency and simplicity
Help to implement a cultural shift in how team members viewed CI and its benefits to individual and departmental efficiency, clarity of roles and responsibilities, and visibility of what good looks like
Operations Director 2020 – 2023
HAECO Cabin Solutions - Greensboro
HCS 8010 Piedmont Triad Parkway Greensboro, NC
Managed the fabrication of composite goods for airline reconfiguration programs
Initiated and facilitated KAIZEN events to help improve overall efficiency of the Interior Fabrication Shop
Improved efficiency from 30% to above 75% during 3 quarters of operation
Developed reporting generated from the ERP systems to clearly define shortages which greatly improved the reaction time in getting parts to the stations when needed to support deliveries
Manufacturing Engineering Director 2017 – 2020
HAECO Cabin Solutions - Greensboro
HCS 8010 Piedmont Triad Parkway Greensboro, NC
Created a methods organization from the ground up which included new product introduction, product data management, sustaining, CNC services, and tooling design and manufacture
Developed systems to systematically implement the release of new engineering from initial release to engineering change from product launches
Developed process and reporting functionality to control how part parameters were loaded into the ERP system to drive proper demand
Initiated process changes and improvements into production at various production cells to modernize production processes merging new machine technology and old-world techniques
Operational Excellence Director 2016 – 2017
B/E Aerospace - Tucson
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Trained to train Golden Triangle Lean Methodology which focuses on standardized work, visual management, and standardized management.
Managed cascade of Golden Triangle to Directors and next level management.
Organized KAIZEN schedules and CI charters for all events.
Launched Policy Deployment for Tucson facility in 2017
Manufacturing Engineering Director 2015 – 2016
B/E Aerospace - Tucson
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Managed ME teams on multiple program launches.
Presented Departmental KPI’s to senior team.
Manufacturing Engineering Senior Manager 2014 – 2015
B/E Aerospace –Nogales/ Tucson Operations
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Aligned both Tucson and Nogales Manufacturing Engineering Departments.
Set up training schedules and modules for entire departmental activities.
Manufacturing Engineering Manager 2012 – 2014
B/E Aerospace -Nogales Operations
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Part of the senior management team involved in high level strategic planning and problem solving.
Product Data Management for ERP system.
SUMBOM generation for MRP driven activities
Organize New Program Launches which includes PDM activities, tooling requirements (design, procurement, and fabrication), CNC programming, bonding fixtures, production support for test / production units, and quality criteria (fixturing, measurement methods, etc.).
Manage methods teams for (6) core competencies: Compression molding, Vacuum molding (curved honeycomb panel), Honeycomb structures (flat panel and bonding processes), Cut and Sew (seat parts), Aqua graphic printing, and mechanical assembly (table and video mechanisms, armrest assemblies).
Provide competitive quoting to new and existing customers to expand and grow the business.
Manufacturing Engineering Supervisor January 2008-May2012
B/E Aerospace - Nogales Operations
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Establish a Methods Engineering Department in the Nogales division producing parts for Super First Class Environments.
Open up the lines of communication between both sites (Tucson and Nogales).
Provide initial training to all Nogales employees on transferred processes from Tucson and new processes acquired in the UK (compression molding).
Develop standards and flow diagrams for all Nogales department activities.
Form ties with other sister companies to achieve newly awarded product to reach company growth targets of 30% a year
Perform requirements needed to successfully drive 5 Axis CNC machining into Nogales processes.
Manufacturing Engineering 2007- 2008
B/E Aerospace - Nogales Operations
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
Perform ERP maintenance for ECO driven configuration changes.
Load ERP with BOM’s and routing.
Design and organize the fabrication of production tooling.
Create work instructions for new program launches.
Part of the initial Tucson Support Team to set up operations in a newly conceived plant located in Nogales, Sonora Mexico
Produced original facility layout for the Nogales plant
Transferred flat panel production process to the Nogales plant.
Manufacturing Supervisor August 2000-October 2007
B/E Aerospace – Tucson Operations (Bomhoff Acquisition)
B/E Aerospace 1851 S. Pantano Rd. Tucson. Arizona 85710
In charge of production teams that produced Super First Class interiors.
Developed many standards to produce product using lean tools and innovative tooling philosophies.
Worked directly with design engineering teams to design SFC environments that were in tune with established manufacturing techniques.
Provided field support as necessary for new program installations.
Shop Supervisor 1995 - 2000
Centerline DH Woodworks
Tucson, Arizona
Produced high end furniture and cabinetry for residential applications.
Managed a crew of both shop fabricators and installation crews (25+ employees).
Designed and drafted shop drawing per customers requirements.
Performed on site support to customers from design to installation to warranty requests.
Skills
Highly skilled craftsman in both conventional woodworking and aerospace interiors.
Able to manage very large organizations.
Fluent in Spanish.
Well developed tooling background for assembly of cabinetry, vacuum and compression molding.
Well versed in 3D Modeling.
Budget management
Extensive ERP and MRP experience
Lean manufacturing tools.
Well travelled to Europe, Canada, and Mexico.
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