Continuous Improvement Quality Management

Nelson M. Rocha

** ******** ******, *****, ** L*A 2P4

Mobile: 437-***-**** Home: 905-***-****

E-mail: ******.*****@******.***

SUMMARY OF QUALIFICATIONS

Over 20 years of operational excellence and change management experience, implementing world-class, lean manufacturing initiatives in various industries including automotive, distribution, aerospace, energy services, and window & door manufacturing.

Seasoned Production Manager with a proven track record of engaging the workforce in achieving strategic goals and objectives in Safety, Quality, Delivery, and Productivity, overseeing up to 200 employees across 3 shifts 24/7 in a fast-paced, unionized work environment.

Certified Lean Leader through Continuous Improvement Leader Certification Program (ArvinMeritor) and SMS Champion Certification Program (ShawCor), and Six Sigma Green Belt (ArvinMeritor).

Certified auditor experienced in ISO quality/environmental standards and health & safety management. SKILLS AND ACCOMPLISHMENTS

Awarded for the highest achievement in Health and Safety initiatives and KPIs, receiving the 2022 Health and Safety Excellence Award (2021 Honourable Mention).

Trained as a Six Sigma green belt, received global recognition with a "gold award" for a team project resulting in

$160,000 in savings annually applying Six Sigma methodologies.

Successfully implemented a robust production scheduling process for all departments for the fabrication of custom window and door assemblies, increasing on-time delivery from 45% to 85% in 3 months.

Completed 20 Kaizen Events within a fiscal year resulting in $600,000 in savings.

Selected by peers as valedictorian for the 13-week Site Continuous Improvement Leader Certification Training.

Successfully managed a customer-driven certification program for lean initiatives, completing re-certification in December 2012 (Bombardier 5-Star).

Participated in the transition from ISO 9001 to TS16949 certification as a member of the internal auditing team, authoring most production-related Standard Operating Procedures, documents, and process flow diagrams.

Conducted 25 4-day workshops training over 500 participants over a 3-year period on Lean introduction program.

Proficient in Microsoft Office suite including Word, Excel, PowerPoint, Outlook, Teams, SharePoint, and Project.

Experience with various MRP and ERP software including AS400, M1, SAP, Oracle, Red Prairie, and Epicor. CAREER HISTORY

Toro Group of Companies - Toro Aluminum, Vaughan, ON Production Manager Nov-2020 to May-2024

Manufacturers of quality windows and doors for high-rise condominiums, office buildings and hotels, across Canada, the United States and Mexico

Reporting to the Plant and Purchasing Manager, oversaw one of two production plants and the main warehouse facility with 8 supervisors and 200 employees over 3 shifts (days, nights, weekends) in a union shop.

Successfully leveraged untapped capacity by crewing up supervisory and hourly staff on off-shifts to meet customer demand, increasing throughput by 100% in the first 3 months of the year compared to the average output of the previous 3 yrs., reducing backlog and increasing on-time delivery.

Leveraged the existing Safety Hazard reporting system to incentivize and reward employees through various raffles to increase engagement.

As acting management co-chair of the Joint Health and Safety Committee, adhered to a cadence of consecutive monthly meetings for 36 straight months.

Facilitated the implementation of parts bar-coding and RFID labeling initiatives to improve parts cutting completion and delivery accuracy.

Instituted a formalized cycle counting process in the warehouse and Standard Operating Procedures resulting in improved inventory accuracy, resulting in 4 successful year-end inventory audits. Nelson Rocha, Résumé 1 of 4

Jeld-Wen of Canada, Vaughan, ON

Continuous Improvement Manager Sep 2018 to Oct 2020 One of the world’s largest manufacturers of an extensive range of interior and exterior doors, vinyl windows, and related products for the new construction and repair and remodeling of residential homes

Responsible for the implementation of the Jeld-Wen Excellence Model (JEM) lean program throughout the site.

Standardized SQDCI Boards and daily start-up meetings across the plant, for all departments, providing visual daily metrics and countermeasure tracking.

Managed capital investment projects totaling $10 million CAD in the replacement of outdated equipment with newer, reliable technologies, visiting vendors globally to complete Factory Acceptance Testing of equipment.

Established a pipeline of projects for 2019 and 2020 to achieve site targets of 5% productivity improvements.

Introduced standard A3 methodology for the management of site projects.

Mentored and trained Group Managers on basic problem-solving skills for Safety, Quality, Delivery, Cost, and Inventory-related opportunities to drive root causes.

Facilitated a kaizen event in the assembly area resulting in a 15% increase in throughput using cycle time analysis.

Implemented Operator Safety and Preventive Maintenance Checklists, achieving safety compliance and reducing downtime on the glass manufacturing line by 25%.

Axalta Coating Systems, Ajax, ON

Continuous Improvement Manager Feb-2016 to Aug-2018 Leading global coatings systems company that manufactures, markets and distributes paint for commercial vehicles, refinish aftermarkets and a wide variety of industrial coating systems

Responsible for the administration and management of site continual improvement program.

Identified and provided leadership in the development and implementation of new manufacturing techniques to reduce cost, improve quality, and increase safety.

Prioritized and implemented schedules for assigned projects using appropriate planning methods and facilitated project implementation.

Provided tactical coaching on Lean Methodology and Continuous Improvement Techniques to the Production team.

Served as a facilitator and coach for 5S and Lean Teams during Kaizen events and follow up to assist supervisors in sustaining improvements. Resulted in a 20% improvement in 5S audit scores in 3 months.

Led investigations into safety and quality incidents through root cause analysis and respective countermeasures. 22 investigations completed with zero repeat incidents.

As the area "landlord" of Finished Product, participated as the lead liaison with TS16949 auditor, reviewing FMEA, Control Plans, and Standard Operating Procedures and Work Instructions resulting in zero findings.

Implemented a standard Visual Display Board to facilitate Daily Production and shift turnover process. Alumicor Ltd., Toronto, ON

Operations Manager Mar-2015 to Jan-2016

Leading, Canadian-based supplier of architectural aluminum building envelope systems for the industrial, commercial and institutional markets in both new construction and renovation

Reporting to the VP of Operations and responsible for the Ontario market, managed the plant team (manufacturing, scheduling/planning, quality, shipping/receiving), including mentoring and developing staff.

Contributed to and implemented the rolling 3-year strategic plan for Operations.

Developed and executed departmental budgets. Responsible for full P&L. Reviewed and reported results monthly.

Oversaw, supported, and enforced Alumicor’s Health and Safety Program resulting in 0 lost-time accidents.

Set and managed performance targets for direct reports.

Interfaced with Product Development, Information Systems, Inside Sales, Sales & Finance functions.

Responsible for recruitment, hiring, training, performance management, and terminations.

Monitored financial performance to ensure the facility is meeting or exceeding budgetary commitments.

Actively participated, supported, and drove lean/continuous improvement initiatives.

Implemented a robust production scheduling process for all departments for the fabrication of custom window and door assemblies, increasing on-time delivery from 45% to 85% in 3 months. Nelson Rocha, Résumé 2 of 4

ShawCor Ltd., Toronto, ON

ShawCor Management System (SMS) Coordinator Jul-2013 to Dec-2014 (12-month contract - extended) Global energy services company focused on technology-based products and services for the pipeline and pipe services market and the petrochemical and industrial markets

Reporting to the Vice President of SMS, Corporate Operations Group, headquartered in Toronto.

Supported Corporate ShawCor Management System (SMS) team in training initiatives for lean, SMS Champion Certification Program globally for Senior-Managers, Managers, and Supervisors.

Coached SMS Champion Certification participants through a 6-month training program, monitoring test and assignment results based on learning specifications and program framework.

Developed online testing criteria for the training program using TestGenerator application.

Prepared and developed training materials and coordinated logistics for training events and webinars.

Acted as principal support for SMS Managers for training and implementation activities.

Developed global standards across all divisions for operational and Service Quality metrics.

Conducted a review of annual Business Strategy Plans to identify performance gaps in financial, SMS, and HSE metrics and to ensure alignment with the overall strategy, cost savings plan, and lean initiatives.

As a project lead, developed a global SMS SharePoint intranet site, creating templates, standards, and Best Practice sharing workflows for the entire organization.

Supported registration and planning for over 140 ShawCor delegates worldwide during the 2013 AME conference. Koss Aerospace, Mississauga, ON

Continuous Improvement Manager Aug-2012 to Jun-2013 Tier-1 manufacturer of structural aircraft components and assemblies serving commercial aerospace and defense customers worldwide with in-house capabilities for machining, processing and assembly

Responsible for training and educating continuous improvement concepts to the organization and implementing methodologies including Lean, 5S, TPM, SMED.

Tracked and monitored productivity through the use of Epicor ERP system.

Developed and tracked Key Performance Indicators (KPIs) creating accountability to metrics.

Led weekly management meetings reviewing KPIs and implemented corrective actions.

Successfully managed a customer-driven certification program for lean initiatives, completing re-certification in December 2012 (Bombardier 5-Star).

Responsible for Health and Safety management, meeting regulatory and legislative requirements as co-chair of the Safety Committee and acting liaison to the WSIB and Ministry of Labour.

Contributed to the successful completion of the Employee Handbook communicating company policies and procedures standards regarding HR, Health & Safety, Environment, Quality, and Lean. Meritor Aftermarket Canada Inc., Brampton, ON

Workplace Improvement Coordinator Mar-2010 to Aug-2012 Distributor and supplier of replacement parts for trucks, trailers, buses and vans across the globe under industry-leading brand names

Principal operations support, management representative, and change agent for quality assurance, continuous improvement, health, safety, and environment.

Implemented an employee suggestion program resulting in $23K savings in the first year.

Formalized Process Improvement Events (Kaizens) completing 4 events in the first year with $39K in savings.

Developed and administered 5S program, including the office, resulting in a 10% YOY audit score improvement.

Responsible for the development and improvement of Corporate Safety Management programs to ensure regulatory and legislative compliance for 3 Canadian operations (multi-provincial).

Conducted Workplace Inspections and managed safety meetings as Committee Chair.

Lead Auditor and management representative for ISO 9001 and ISO 14001 (2 years – 0 major findings).

Facilitated the transition of MRP system from AS400 to Oracle with Red Prairie WMS System.

Oversaw implementation and initial cadence of a Daily Management System improving communication to all employees on the company’s overall objective and targets. Delegated management of the process to Supervisors. Nelson Rocha, Résumé 3 of 4

ArvinMeritor Inc., Toronto, ON

Site Continuous Improvement Leader May-1999 to Sept-2006 Production Supervisor Dec-1994 to Apr-1999 and Oct-2006 to Sep-2009 Global, tier one supplier of original equipment and aftermarket ride control products to the commercial vehicle, recreational vehicle and industrial markets

Promoted to Site Continuous Improvement Coordinator in May-99 until Sep-06.

Assessed, developed, and implemented lean manufacturing strategies that supported the achievement of strategic business objectives for both production and non-production processes.

Conducted over 20 4-day Lean workshops (Arvin Total Quality Production System) with over 450 participants, introducing employees, customers, and suppliers to lean concepts.

Completed 20 Kaizen “Process Improvement Events” in 2006 resulting in $600,000 in savings.

Managed and audited all departments to corporate Lean certification program, becoming the first organization globally to achieve “World Class” recognition for all departments.

Developed and managed an employee suggestion program resulting in 10 suggestions per employee at an 85% implementation rate. Achieved $250K savings in one year.

Managed 30 hours of training per employee for 500+ employees at its peak period.

Chaired monthly management meeting on the status of lean implementation based on established metrics.

Implemented weekly team meetings for all production and office teams promoting employee involvement.

Trained all employees in 5S initiatives and implemented monthly audits for all departments.

Developed and implemented TPM (Total Productive Maintenance) program resulting in a 30% increase in uptime resulting in increased throughput and productivity.

Implemented and improved plant-wide communication strategy sharing site objectives and metrics.

As Production Supervisor, created production schedules in various departments through MRP system (IBM AS400) to maintain optimal material flow and minimize waste to meet customer delivery dates.

Experienced in tube manufacturing and cutting, stamping, press welding, packaging, and paint processes.

Managed 200+ employees in a fast-paced working environment in various departments including sub-assembly, assembly, packaging & paint.

Implemented/audited procedures to ISO 9001 and ISO 14001 standards as a member of the site auditing team.

Responsible for Safety, Quality, and Productivity results in all departments and implementing Lean initiatives.

Introduced a new product line and assembly process for “Big-3” customer in an accelerated time frame resulting in 100% on-time delivery and 0 ppm in the first 6 months of launch.

Managed progressive discipline, job posting, and overtime records process as per collective agreement.

Member of the site Diversity Council and Social Committee organizing various fundraisers and events. EDUCATION AND TRAINING

ShawCor Management System Champion Certification Program (ShawCor)

Program Management Essentials (Franklin Covey)

Site Continuous Improvement Leader Certification Training -13 week Program (ArvinMeritor)

Six Sigma - Green Belt (ArvinMeritor)

Arvin Total Quality Production System 4-day Lean Workshop (ArvinMeritor)

Arvin Total Quality Administrative System 3-day Lean Workshop (ArvinMeritor)

5S, Standard Work, Kanban, Quick Changeover “train-the-trainer” sessions (ArvinMeritor)

Value Stream Mapping and Process Flow Charting including “train-the-trainer” (ArvinMeritor)

Changing Role of Managers and Supervisors including “train-the-trainer” sessions(ArvinMeritor)

Total Productive Maintenance – Intro. & Intermediate including “train-the-trainer” sessions (ArvinMeritor)

Kaizen “Process Improvement Event” Planning (ArvinMeritor)

Failure Mode & Effects Analysis, Product Safety & Compliance Training (ArvinMeritor)

ISO/TS 16949:2002 Internal Auditor Training (BSI Management Systems/Axalta)

ISO 14001/QS 9000 Internal Auditor Training (BSI Management Systems/Axalta)

Certified Joint Health and Safety Committee Training – Level II (IAPA & Safety One Canada) Nelson Rocha, Résumé 4 of 4

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