Cesar Carassa

**** ********* **.

add05c@r.postjobfree.com

Ada, MI 49301

C: 616-***-****

A dedicated Industrial Engineer experienced in all aspects of Process Improvement focus on waste, cost, lead-time reduction, and quality perfection. With international experience. Academic credentials Black Belt in LSS, Master in Finance, and BS in Industrial Engineering.

Selected Highlights

Developed and implemented projects reducing operative cost by 25% generating savings of $1.6 million/yr.

Cost reduction by $250K yearly as a result of process improvements (kaizen).

Reduction of inventory by 40% by effective Kanban implementation. Generating cash-flow of $450K monthly

Contributed to strategic development and implementation of continuous improvement procedures, increasing revenue by 250% in 5 years.

Trained people and managed all the quality aspect reducing the returns by 50% yearly by identifying quality control in critical processes, establishing best practice habits.

Developed KPI to evaluate performance and improvements.

Demonstrated Skills & Knowledge

Continuous Process Improvements

Statistical Process Control

Cost controls/reductions

Expansion /turnaround strategies.

R&D/engineering operations

Start-up operations/organization.

Plant operations systems design

Financial planning & analysis.

Professional Experience

Director of Operational Excellence

California Closets, (custom furniture manufacturer)

2018-Current

Developing and establishing a Quality System, with clear QA processes and methodologies. Defined new SOP company policies. Leading a team project to reduce in 69% non-conforming products.

Implementing Kanban systems at two plants increasing OEE 30% reducing wait time in 50% in packing

Leading team kaizen/continuous improvement projects, apply ideas/concepts to daily job

Value Stream Manager

California Closets, (custom furniture manufacturer)

2015-2018

Reduce lead time from 3 days to 3 hours by reducing batch sizing, implementing clear VSMs. Providing root cause /countermeasure, PDCA, and A3 training dropping cost and improving quality.

Leading team kaizen/continuous improvement projects, apply ideas/concepts to daily job

Propose cost saving projects in a 5 years’ plan, including the start-up two new manufacturing centers

Developing CI/SOP/WI for several plants and distribution centers

Ensuring compliance towards safety policies and regulations

Providing new methods/improvement solutions in efficiency and quality.

Lean Manager/Plant Manager at Easy Closets (Pinebrook, NJ)

The Stow Company, Holland MI (furniture manufacturer custom and high volume)

2010-2015

Acting as a Plant Manager for over 8 months at Easy Closets.

oIncreased productivity in 76% by developed VSM, PDCA archiving a reduction in 30% in labor cost.

oIncreased inventory rotation 10 times by implemented the Kanban system. Reducing the WH area by 45%.

oParticipated and executed onboarding plans to move the plan to Holland, MI

Established KPIs and set up daily goals, reaching the goals up 95%, with employee engagement.

Developed training and trained key employees on Lean methodology (VSM, one-piece flow, JIT, TPS)

Partners with other Department Managers to execute critical projects for business growth

Plant Manager

Scott Group, Grand Rapids MI (custom carpet company for private and residential)

2003-2010

Increased productivity by 20% by reduced cycle time from 14 to 6 weeks by Kaizen workshops as a primary strategy for cost-saving initiatives & employee engagement over 120 participants growing the company from $5 to $30 million in 6 years.

Expanded market share 18% by process improvements, requested by these new customers. Developed new markets, by introducing new products (DFSS) in a very high-end market, these products produced 70% profits

Developed and introduced production metrics and scorecards, by using SPC also created new procedures, equipment, and tools to eliminate product mistakes.

Developed Quality Manuals and procedures, Trained people, and managed all the aspects of Quality, reduced the returns 50% yearly by identifying quality control in specified processes, establishing the best practice habits.

Developed and evaluated Root Cause Analysis resolving difficult equipment and operational problems. Analyzing and establishing new procedures.

Monitored all the aspects of quality control to get ISO9001 certification. Included travel globally to the customer, resolving any quality complaint on-site, providing technical support, getting quality standards approval, filling surveys, and non-conforming reports.

Manufacturing Engineer

Kalogridis International, Dallas, TX (custom carpet manufacturer in private jets)

1997-2003

Improved Costing process in custom products. Increased profits by 17%, saving over $2MM/yr.

Worked with our supplier, we reduced the cost of $78,000 per year, eliminating unnecessary steps.

Reduced lead time and increased our delivery on time by 83%, by introducing a new scheduling process. To meet scheduling delivery dates for on-time shipments by creating a database with strict drop dates by the department.

Developed and Maintained all aspects of quality control to obtain ISO9001 certification.

Introduced and sustained bi-monthly safety meetings, facilitated safety training, with PPT presentations.

Technical Support Engineer

Wilcom Pty. Ltd, Sydney, Australia (carpet machine manufacturer)

1992-1997

Played a central role in efforts to penetrate the global markets with a new product. Commissioned and start-up manufacturer factories in England, Spain, France, Australia, United States.

Improved Customer Retention by 15% by provided troubleshooting service & technical support 24-7 global clients.

Established an engineering and maintenance evaluation process for identifying improvement opportunities.

Increased productivity by 25% by improving performance with new raw material.

Earned several promotions from Machine Operator up to Production Engineer.

Plant Manager

Hogar, Lima, Peru (textile home products)

1986-1992

Increased productivity level by 35% by reducing scrap, generating $220K in savings.

Accomplished JIT schedule for OEM’s as Toyota/Nissan and carpet installation, reducing lead-time in 40%

Represented management in union negotiations. Exceeded production goals. Recognized as an effective negotiator, generating the highest level of revenue of $1.4 million.

Education

Black Belt Lean Six Sigma. Dalton, Georgia.

Master in Finance, Postgraduate School of Business administration, Lima, Peru.

Bachelor of Science in Industrial Engineering, University of Lima, Lima, Peru.

Fluent in Spanish.

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