Plant Manager Engineer

Robert J. Mohrmann

BSEE

*** * ****** ***. ***-**3 email: *********@*****.*** Cell 915-***-****

El Paso, TX 79912

Plant Manager / Operations Manager / Quality System Manager / Engineering Manager

Experience: Extensive manufacturing experience with Ford Motor Company, Visteon Corporation, Halla Visteon and Hanon Systems in ascending leadership positions including Plant Manager, Sr. Manager Quality, Manufacturing and Product Development Engineering Manager. Broad based cross-cultural experience with assignments in Mexico, Czech Republic, Canada, with programs in Korea, and Portugal

QUALIFICATIONS

Operational Excellence – Led efforts to transform operations through deployment of OPEX. Improved 5S practices and established standardized work. Implemented layered process auditing though all levels of management Promoted clear shop floor communication by utilizing visual factory principles and team huddle boards to actively manage progress towards objectives, drove daily accountability to an individual level

Continuous Improvement – Promoted disciplined data-driven approaches to process optimization, including targeted Six Sigma projects, Kaizen activities, Go & See events and Built-In-Quality (BIQ) process improvement methods. Applied Lean Manufacturing techniques to eliminate waste have successfully maintained ISO/TS 16949 and ISO 14001 certification, Attained Q1 Rating for 3 facilities. Transitioned Facilities to IATF

Leadership – Emphasized management visibility on the shop floor. Led and developed a cross-functional teams of over 500 people, involving Operations, Finance, Engineering, Supervision, Maintenance, Logistics, Human Resources and shop floor employees. Developed an environment valuing teamwork and integrity stressing structure and accountability.

Proven ability to make the hard decisions to improve the business.

Fiscal Responsibility –Led the development, construction and launch of a new $92 million air conditioning compressor manufacturing plant, delivered under capital expense budget. Launched multiple heat exchanger and Fluid Transport lines, on time, on budget, Improved Plant Labor and Overhead performance of each assigned plant

PROFESSIONAL EXPERIENCE

Hanon Systems (Formerly Halla Visteon) (2015-Pres)

Spun off from Ford Motor Company in 2000

Mexico Launch Leader and Global Labor and Overhead Cost Leader (March 2020 –Present)

Responsible for successful new model launch for plants located in Mexico (6 Facilities)

Globally responsible for Labor and Overhead cost controls (30 Facilities)

Plant Turn around Leader, Queretaro Mexico (November 2019 – March 2020)

Distressed Facility failing to meet customer volume requirements, excess scrap and labor

Developed labor structure to support plant floor production

Utilized Subject Matter Experts from other facilities to address issues and fill gaps

Simplified process flows through machine rebalance and brought in additional surplus equipment from other facilities

Increased production output by 65%

Implementation visual shop floor management

Multi-Site Plant Manager, Belleville Canada (October 2018 – November 2019) (Traveler 3 weeks Canada 1 week Mexico)

Plant Manager 3 Facilities in Ontario Canada 2 Facilities in Belleville, 1 Facility in London

Fluid Transport, HVAC, Electronic Throttle Body, Electric Valve Product Lines.

Right sized the Operations and Addressed Labor and Scrap Costs.

oDeveloped Plan to address underutilized Square Footage

oLeaned out production Lines through use of “Most” and consolidate operations where available.

oImplementation of Automation where business case makes sense to reduce labor.

oImprove Management Focus on scrap and waste reduction

oShuttered one Facility and exited non profitable, non-core business

oExercised Sale Leaseback on one facility to take advantage of High Market prices and free up capital.

oLaunched 3 new lines to support Ford and GM.

Acting Multi Site Plant Manager, Novy Jicin Czech Republic.(June 2018 – October 2018) (Traveler 3 weeks Czech 1 Week Mexico)

Fluid Transport Products for A/C systems.

Distressed Facility

Improved Plant Performance.

oIncrease production levels to remove Premium Freight

oImplementation of Standardized Work

oRight Size the labor requirements through development of BWS and CWS work standards

oImprove Quality via fast response, standardized work, Accountability and Read Across.

Plant Manager, Coclisa Paso del Norte (July 2015 – June 2018) Juarez, Mexico

Full P&L Responsibility for Radiator, Condenser, Heater Core, TOC and HVAC Manufacturing Operations

Tasked with launching 8 new products in 2016

oKia Radiator – Complete

oKia Condenser – Complete

oKia Heater Core – Complete

oHyundai Heater Core – Complete

oAudi Radiator 3 Models – Complete

oFord Fusion Transmission Oil Cooler – Complete

oBRP Shift Radiator - Complete

Achieved 0 PPM Quality in 2015 1.8 ppm in 2016 2016

7% Labor and Overhead improvement in last 2 years

1.7M in Efficiency Savings implemented in 2016.

VISTEON (Halla Visteon) CORPORATION (2000-2015)

Plant Manager, Coclisa Santa Fe Plant (June 2011 – June 2015) Juarez, Mexico

Full P&L Responsibility for Evaporator, Condenser Manufacturing Operations

Successfully Launched Condensers and Combo Coolers for Ford Taurus, Flex, Edge, and Explorer on time, on budget without quality issues. Q3 2011 –Q2 2012

Successfully Launched Ford Focus Condenser in Q3 2012

Successful launched Battery Chiller for Ford BEV Q1 2012

Successfully Launched Tube Fin Evaporator for Ford Escape and Transit Vehicles for US and Europe.

Consistently met and improved on budget for labor and overhead costs at the plant.

Improved Labor and overhead percent of revenue from 25% to 17% from Q3 2011 to Q2 2013 and 17% to 13.5 % Q3 2013 to Q2 2015

Launched Six Sigma with Hourly and Salaried to a level of 4 black belts 17 salaried green belts and 14 hourly green belts driving improvement actions across the plant.

Plant Manager, Coclisa Chamizal Compressor Plant (2010 – June 2011) Juarez, Mexico

Full P&L responsibility for Compressor manufacturing operations, generating $71 million in sales with an operating budget of $12 million, Leading an energetic, creative team focused on Continuous improvement.

Achievements

Team has established 6 sigma training for engineers and supervisors certifying 5 green belts and one black belt in training with booked savings of $111 thousand.

Team has implemented process improvements and has improved profitability by $450 thousand better than budget commitment.

Team has implemented cost control actions to monitor and control overhead costs during industry upswing.

Team has operated on average 20 heads under budgeted headcount through out the year, utilizing cross training, improved scheduling and operational efficiencies to maintain a stabilized workforce.

Team has implemented additional cost control actions to limit overhead costs such as, Utilities Monitoring, Shutdown Checklists, and Office utilization for HVAC reduction, Air pressure controls etc.

Team leads QIT (Cross company forum for like products) to implement best practices, discuss operations and performance issues and promote read across.

Team successfully completed 2 years without a lost time accident.

0 PPM Performance 2011. 17 consecutive months without customer quality issue.

Sr. Manager Quality Systems, Cross Site Responsible 4- Manufacturing Facilities and Distribution Center (Sept 2008 – 2010) Juarez, Mexico

Cross site responsible for Quality Operations including, Customer and Staff interface, procedure establishment and compliance to TS/ISO and customer specific requirements. Maintain and track all Quality Operating System Metrics.

Achievements

Reduced PPM 2008 27, 2009 20, 2010 8, 2011 6 2012 6 across 4 manufacturing facilities.

Attained Q1 Rating for all Facilities

Drove Quality Inspections down to lowest levels of manufacturing vs. utilizing dedicated inspectors.

Successful recertification of TS16949 and ISO 14001 for 4 manufacturing facilities and distribution center

o2011 audit completed with zero non conformances.

Established positive customer relationships through, fast response, transparency, and improved communication.

Reorganized Quality department to meet the needs during the industry downturn.

Decentralized manufacturing specific quality operations to become part of the manufacturing team vs. a policing organization.

Compressor Manufacturing Engineering Manager, Coclisa Chamizal Compressor Plant (2007-2008) Juarez, Mexico

Machining and Assembly Manager responsible for Launch to Production Coordination of Machining and Assembly operations for 2.4M Capacity Compressor Plant, Leading a team of highly motivated engineers to improve OEE of operations and deliver to cost and quality targets Coordinate with customers all aspects launch, timing, quality and PPAP.

Achievements

Improved compressor profitability by $24.2 million

Improved First Time Through by 32% though coordinated manufacturing and design improvements.

Reduced labor and overhead costs by 68%

Compressor Launch Engineering Manager, Coclisa Chamizal Compressor Plant (2005-2007) Juarez, Mexico

Responsible for the specification, runoff and installation of over 100 machine tools and two $12 million assembly rooms to establish a state of the art compressor operation. $92 Million project. Coordinated with all machine tool suppliers to support timing and cost objectives.

Achievements

Delivered $68.7 million in new compressor business over 16 month period.

Launched operations on time and reduced capital investment by $3.6 Million

Developed flexible manufacturing systems to accommodate complexity with low/no changeover

Compressor Applications Manager, Climate Staff Office, Plymouth, MI. (2003-2005)

Coordinate with Korean operations (Halla Climate Control) for design, launch and implementation of FS18 and FS20 compressors, with extensive travel to South Korea. Led small team of application engineers to cover all customer interface activities related to compressor implementation while guiding Korean operations though customer requirements.

Achievements

Successful completion of Ford “Clean Green” reliability discipline

Successful attainment of Ford Q1 for manufacturing location.

Scroll Compressor Product Development Manager, Climate Staff Office, Plymouth, MI. (2001-2003)

Lead team of current model engineers to implement cost reductions and reliability improvements on scroll compressor designs being manufactured in Connersville Indiana and Palmela Portugal.

Achievements

20% reduction in warranty costs.

9% reduction in material costs.

Electric Compressor Design Manager, Climate Staff Office, Plymouth, MI. (2000-2001)

Performed R&D into Automotive Application of Hybrid and Electric Compressor Systems with small group of designers

Achievements

Awarded 4 Patents for Hybrid Compressor

Inventor of Dual Drive Scroll Compressor

Ford Motor Company (1992-2000)

Scroll Compressor Design Engineer, Climate Staff Office, Plymouth, MI. (1997-2000)

Clean Sheet Design of SC115 and SC105 scroll compressors manufactured in Connersville, IN and Palmela Portugal. Awarded Patent for Scroll Bearing Design

Maintenance Planning Specialist, Connersville Plant, Connersville, IN (1995-1997)

Planned all maintenance activities and spare parts for Condenser area containing over 400 machine tools Launched department’s first TPM program, “Running PM” Program

Manufacturing Engineer Radiator, Connersville Plant, Connersville, IN (1994-1995)

Engineer responsible for Radiator core building operations. Redesigned and rebuilt 4 obsolete core builders into current model product to increase capacity and save investment. Designed and Implemented modifications for Conversion to CAB brazing process.

Maintenance Supervisor, Connersville Plant, Connersville, IN. (1992-1994)

Supervised Crew of 15 Journeymen Skilled Trades. Implemented Departments first Furnace Maintenance Program. Implemented OEE tracking for departments bottleneck operations

COOP Student, Guardian Industries, Corsicana TX (1985-1990)

Engineering COOP with multiple assignments in Guardian Float Glass Operations, Including Hot Work, Production, Inspection, Sales, Quality and Engineering.

Education

BSEE – University of Texas at Arlington, Arlington, TX (1992) - Deans List recipient.

Kettering University (GMI) 1986-1990 – Electrical Engineering Major

Earlham College, Executive Development – Richmond Indiana (1996)

4yr Honor Graduate – Ennis High School, Ennis, TX. (1985)

Numerous corporate education programs & seminars on various Engineering Disciplines, Project Management, Employee Management.

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