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Manufacturing Manager / Operation / Warehouse / Quality

Marietta, GA
February 20, 2020

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Ferdinando Castrillon-Zapata 404-***-**** Cell

Marietta, GA 30008


Seasoned Bi-Lingual business professional with over 15 years of leadership experience in manufacturing operation, seeking an opportunity in a Manufacturing Production/Warehouse Manager role within an organization to motivate others, increase productivity, improve business unit process, new product development, employee retention and help influence change in the business bottom line.

Summary of Qualifications

15 years experience in Manufacturing Operations

Six Sigma - Green Belt Certification – SPC and Process capabilities

5 years experience in Operation Management, Safety Manager & Warehouse Management

3 years experience in Quality Assurance - ISO 9001-Quality System Management

Lean Manufacturing Certification - 5S / Poke-Joke Methodology

P&L Management / Project Management and R&D (New product development and implementation)

Experienced in OPEX,GMP, TPM,OEE, Kaizen Events and KPI Management

MRO Experience in Aviation H1, Metal Fabrication and Line Cell Assembly.

Bilingual-Fluent in Spanish, both written and verbal

Experience with IATA and IMDG Regulations

Certified OSHA to include EH&S and HAZMAT Training

Productivity improvement, RMA analysis- 5 why’s and staff /team development

Experienced in staffing, training, motivating and evaluating personnel

Production Planning, organizational skills, team building and problem-solving capabilities,

High-energy, self-starter with ability to establish and maintain an efficient and highly productive work force.

Proficiency in ERP (Visual, Epicor), SAP, Infinity QS, Minitab, BaaN, Kronos, MS Office, Excel, Power Point and Windows Systems

ABS/PP Injection Molding Experience (Automotive and Battery Industry)

Strong mechanical aptitude, Blue prints (CAD/ Solid Works) comprehension.

Professional Experience

ITW July 2016 – Nov 2017

Production / Warehouse Manager

Managed / Lead a team for a chemical product Company for the Industrial MRO, Auto OEM, and Aerospace markets.

Responsible for scheduling, and managing the resources and processes to maximize productivity. Responsible for directing, training, coaching and evaluating department personnel, supporting and leading continuous process improvement programs, safety and quality.

Lead, directed and controlled the day to day delivery goals by optimizing efficiency of the operations to achieve the operating objectives as directed by the division’s business plan.

Coached, trained, and provide concise and clear direction to all direct reports to meet job responsibilities, and optimize productivity.

Managed the assigned production schedule to efficiently support the monthly quota providing hands on analytical and troubleshooting when encountering operational issues. Supported and lead continuous process improvement programs including 80/20, Six Sigma, lean Manufacturing, Just in time, Kanban, etc.

Incorporated new RF scanners system to improve warehouse inventory and streamline the plants quality issues of improper shipments.

Valassis July 2015 – July 2016

Production/ Operation Manager

Managed / Lead a team 2 Direct Report and 45hourly associates in Direct Mail production operations in a timely cost effective manner.

Motivated the team with “On Floor Presence” to meet daily goal with quality standards.

Performed Kaizen event to improve the production Muller Martini equipment efficiencies. Championed, Evaluated and recommended process improvements in the operation – utilizing Six-sigma and lean practices.

Incorporated the “VOA” program to assist in team work communication and address daily concerns.

Manage the maintenance department, Champion the installation of “NEW FERAG” equipment to improve productivity by 30% and reduce labor.

Implemented and maintained preventative maintenance programs, Maintained existing plant facilities and equipment; replace, or made adjustments to plant facilities and equipment when necessary. Prepare and Conducted monthly Safety Meeting for all company employees.

TigHitco (Aeronautical Fabrication) July 2010 – December 2014

Production Manager

Managed the fabrication of an aeronautical organization that produced Stainless Steel, soft and molded blankets that supported – Boeing, Sikorsky, Rolls Royce, Hamilton, gulfstream and other aviation clients.

Managed 7 hand fabrication cells and 1 automation cell to meet daily production goals while motivating 55+ employee workforce to meet customer quality and on time delivery.

Maintained a visible ON-FLOOR PRESENCE to ensure safety PPE, productivity, quality and address all employee issues in a timely manner. Drove lean initiatives throughout the workforce. Performed manufacturing operational strategies, evaluated manufacturing trends, critical measurements and distribution of resources.

Maintained material availability, utilizing an ERP (Enterprise Resource Planning) system.

Developed and managed forecast - Maintained 112% budget forecast monthly to assist the organization monthly sales. Maintained developed manufacturing financial strategies by estimating, forecasting, and anticipating manufacturing requirements, trend and variances.

Performed root cause analysis on quality complaints (RMA’s) – utilizing fish bone and a 5 why’s matrix - lead to developing / implemented corrective action plan to eliminate the root cause. (Product Development) - Lead new project from blue print (model) to full production, working with engineering to ensure 1st article meet the customer specification.

Motivated associate to achieved bottom line measurable results – utilizing the KPI’s board – Top 5 matrix - cost/unit, safety, quality, on time delivery and productivity.

Trained and managed the training curriculum to ensure cells operators’ have required qualification and certification.

Led team offsite – to assist customers with any fabrication issues. Performed lean studies to improve the cells productivity and assist in the APEX – 5s requirements.

Executed require support to effectively maintain the EH&S, ITAR and security activities.

Hayes Lemmerz International Inc. (Automotive Manufacturing) June 2005 – July 2010

Sr. Production Supervisor

Managed the C&C Machine / Injection ABS Molding and Finishing Department for a TIER 1 Automotive Aluminum Wheel manufacturing company.

Led, organized and directed a shift of 25 + hourly employees and 6 Direct Report Sr. Technicians. Successfully supervised a team of Sr. Technician to maintain and operate the Clad Injection Molding and CNC (Computerized Numerical Control) equipment. (Increased the efficiency of the CNC from 72% to 88%)

Enforced all GMP and company policies associated with their position, to include: quality procedures and safety policies.

Incorporated a PM schedule to reduce operational downtime of a $1 million Automated paint line, inspected automated equipment and machines to ensure specific operational performance and optimum utilization. Performed daily audits of SPC (Statistical Process Control) to meet the company SOP.

Managed routine business needs such as payroll (SAP), cycle counts, daily production reports and 5S.

Led several MBF (Managed by Fact) teams to improve the production flow and incorporated new innovation in the automated production line.

Utilized Six Sigma Tools and formal Greenbelt projects to complete assigned task in a timely manner.

Assisted Engineering department in post-analysis of new technology and capital equipment installation.

Provided problem-solving expertise by identifying root causes for problems areas and recommending possible solution. Member of the Safety Committee and Quality Process Review Board.

Trojan Battery Company April 2000 – June 2005

General Assembly, Finishing Production Supervisor

Managed the Vertical Injection PP Molding, General Assembly and Formation /Finishing Departments’ production processes for a battery company, supervising approximately 50+ personnel’s.

Effectively utilized labor hours to maximize product yield and minimize waste. Increased production in the 1st year by 33% and reduced departmental Non-conformance defects by 89%.

Planned, coordinated and prioritized production processes in order to meet customer and management requirements.

Evaluate, developed and implemented cost reduction and scrap control activities to eliminated waste and non-value processes.

Ensured that all safety standards are observed, measured and enforced. Member of the MRB (Material Review Board) and ERT (Emergency Response Team).

Planned, organized, and administered departmental systems, procedures, operation budgets, manpower and controls for cost-effective operation.

Analyze and recommend machinery, equipment and plant-layout requirements to better utilize plant capability. Assisted in the development of ECN (Engineering Change Notification) procedures for design or process change.

United States Marine Corps

Safety Manager/ MRO Manager/ Quality Assurance Manager

Established, coordinated and developed an OSHA and health program which integrates company’s safety policy into all areas and operations. Maintained Safety reports and records of 300 Marines. Manage the Maintenance Repair and Overhaul of aviation aircraft. Perform daily inspection of aircraft.

Managed 8 employees in utilizing regulations, experience and formal training to inspect, troubleshoot and ensure engines, airframes, flight controls, rotors and related systems meet manufacturers' specifications.

H-1 Operations Manager/ Warehouse Manager

Managed, supervised, motivated and monitored 50+ personnel in a flight line / general assembly work environment.

Managed daily operation for 16 H1 helicopters valued at $19,200,000.

Supervised 10 employees in day-to-day warehouse operations.

Education/ Military School and Training

Six Sigma Green Belt Certification– Hayes Lemmerz International – Gainesville, GA

ISO 9001,Lean Manufacturing / 5S – Georgia Tech – Atlanta, GA

Aeronautical/Mechanical Engineering - H-1 Power plants, Rotors and Related Systems- NAS Millington, TN

Aviation Flight School – Naval Academy - Pensacola, FL.

OSHA / Laser Safety- Dallas, TX

SNCO Leadership Management Career Education Program- Marine Corp Institute - Washington, DC

Hazardous Materials Control - NAS Millington, TN

Nuclear, Biological, Chemical Warfare Certification – NAS El Toro, CA

Honors and Awards

* Presidential Commendation * Held “TOP SECRET” Clearance * Letters of Appreciation * Good Conduct Medal

* National Defense Medal * Southwest Asia Medal (Desert Storm/Desert Shield) * Kuwait Liberation Medal

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