SERGIO J. AMARO

** *** ***, ***********, ** *****, Cell 956-***-****

Education: 1991 Universidad Regiomontana Monterrey, N.L. Mexico

Bachelor of Science in Industrial Engineering.

Six Sigma Black Belt Training, Grupo Dextro

Summary

Experienced industrial engineering Lean Manufacturing and six-sigma leader with over 25 years in the manufacturing industry including: 20+ years in the supplier quality area and more than 4 years in production. Demonstrated excellence in implementing successful continuous improvements programs, resource optimization and personnel management using Lean Manufacturing and Six Sigma Principles. With strong experience in die-casting, plating, paint, stamping, springs and assembly processes. Focus on strong team building and mentoring skills. Effective Implementation of cost reductions projects using continuous improvement techniques with recorded savings of more than 2M dollars.

Work Experience

Supplier Quality Manager, BCS Automotive Interface Solutions from Nov 2019 to Jun 2021

Responsibilities include: Responsible for Incoming Inspection Department and Supplier Quality Department with 5 Supplier Quality Engineers. Managing PPAP activities, Quality Concerns to Suppliers (QCCARs), Supplier Corrective actions and Cost Recoveries, Customer Concerns created due to poor quality of components. Managing Supplier performance from suppliers in Europe, Asia and America and monitored the (SQIP) Supplier Quality Improvement Processes performed by SQ Engineers. Support to logistics department with supplier that were affecting the supply chain. Monitored the implementation of Lean Manufacturing and Six Sigma strategies on the supplier base.

Situation: Severe quality problems with components from suppliers from Mexico and North America causing continuous production line stoppages and creating high amount of cost in containment activities. Poor communication to production lines and plant quality personnel on quality problems caused by poor quality on components. High amount of rejected components in MRB REJECT (Material Review Board) area with 250,000 dollars in Quarantine waiting for disposition from suppliers. There were suppliers in Mexico with delivery problems affecting the supply chain.

Actions: Working with SQEs the Containment activities were improved and cost of rejected material was immediately reduced to 80,000 dollars in the first year and up to less than 21,000 on a monthly basis during 2021. Containment costs were reduced up to 75% in the first year making suppliers accountable to problems and eliminating not necessary containment activities. Incoming Inspection procedures were review and updated and department support was significantly improved. Monitored closely the SQIP activities between SQEs and suppliers.

SQEs were sent to suppliers on site to review the delivery issues.

Results: Improved communication with plant personnel on supplier quality issues; suppliers quality performance significantly improved and line stoppages was reduced and eliminated in some areas. SQEs support to production lines was improved with constant review / refresh of quality concepts training and effective corrective actions review by SQE department personnel and all these activities help to alleviate severe/chronic quality issues on components. Overall supplier scorecards were improved minimum by 50%. The SQEs were able to identified the delivery root causes and worked with the supplier on proper planning and where able to resolve the delivery issues.

Quality Consultant / Manager RGBSI From Sep 2017 to Nov 2019

Responsibilities include: Responsible to perform Quality Audits required by Customers to current or potential new Suppliers. Customers –supplier On-site support, VDA and IATF Audits.

On-site support to a Customer plant in North Carolina, Customer processes were audited following GM PFMEA and Control Plan Audit formats. Worked with customer QEs to improved current prevention/detection controls and implemented new controls for more failure modes identified. Provided support to customers suppliers to improve their PFDs, PFMEAs and Control Plans documents in order to reduce rejections. The control Plans and PFMEAs were updated for all sub assembly and assembly processes meeting GM expectation.

A PFMEA Workshop was also done for FCA production lines.

On-site support for a customer supplier in Arkansas. Supplier was struggling to meet customer requirements for die casted / machined parts. Performed an audit to identified areas of opportunity in order to improve the delivery to a customer plant in Mexico and worked with QEs and Program Manager on the action plans needed to improved performance. Worked with QE and customer SQE in the PPAP submission for a new Machined Cell, this was installed in order to meet customer requirements. We also identified problems in the die cast tooling that was also improved by supplier. A Capacity Verification was done to confirm supplier was able to meet customer requirements. Always using Lean Manufacturing and Six Sigma principles to guarantee effective continuous improvements on Supplier Processes.

Other activities done: New supplier Assessment and CQI audits, IATF and VDA 6.3 Audits performed to suppliers. APQP Training, Supplier development and continuous improvement, Managed trouble Supplier- problems with production controls and on time deliveries. On site support to supplier as requested by the customer logistic department because supplier was causing severe delivery problems affecting the supply chain to GM.

Situation: Different quality services and suppliers’ delivery problems for different customers as described above.

Actions: Have been provided support to companies in WI, PA, IL, OH, NC, AR, GA, MI and Mexico for screw machine, die casting, assembly, electronics, cold headed and Powder coating processes. On the delivery problem to GM by Customer’s supplier, we identified the root cause of the deliveries and where monitoring on daily meetings until delivery issues were resolved.

Results: Based on improvements done to PFMEAs and Control Plans the delivery performance was improved to end customers: GM, FCA and Ford. Based on audits findings supplier were able to improve their quality systems that meet customer requirements. Able to work with customer’s supplier to resolve the delivery issues to GM.

Quality Manager/ Quality Systems Manager, IAI Inc. (Molding, pad printing, paint and laser of automotive buttons) Aug 2016 to Jun 2017

Responsibilities include: Responsible for quality activities of 2 plants and direct communication with customers / Responsible for Quality System of IAI of 5 Plants.

Situation: Poor quality on components affecting product performance and causing high defective rate and poor delivery. Company was in QIP status with main customer.

Actions: Implemented processes to monitor the inspection of critical characteristics on key components. Improved customer response and implemented effective actions to correct main problems affecting deliveries.

Results: Deliveries where improved after 2 months base on improvements implemented. Graduation from QIP after 4 months. Resolved main problem reported from customer.

Supplier Quality Engineer, Igloo Products (Manufacturing of coolers) May 2014 to Sep 2015

Responsibilities include: Overview of Incoming Inspection and Suppliers Quality activities with suppliers in USA, Central America and China.

Situation: Poor quality on components affecting product performance and causing high defective rate on customer complains. Specifications on components not clear for effective performance expected on products.

Actions: Implemented procedures to monitor the inspection of critical specifications on key components. Implemented design improvements on components that result in better performance on Finish Goods.

Results: Implemented changes on components design that improve performance on products and reduce customer complaints; estimated yearly savings of 400K dollars.

Supplier Quality Engineer, TS Tech Trim (Lamination process for car seats) Sep 2013 to May 2014

Responsibilities Include: Responsible for Incoming Inspection activities and overview of supplier for fabrics, foam and backing. Support to Plants in Matamoros and Laredo, Mexico and Hidalgo, Texas.

Situation: Severe problems with supplier providing fabrics, high defective rate and poor follow up on corrective actions.

Actions: Implemented Incoming Inspection work instructions and procedures. Effectively manage and improve supplier relationship and development using continuous improvement technics.

Results: Improve supplier communication, suppliers trained on effective corrective actions methods that alleviate severe issues with quality on fabrics such as color and appearance.

Supplier Quality Engineer, Trico Corporation (Wiper Systems Products) Sep 2002 to Sep 2013

Responsibilities includes: Overview the supplier quality engineering in the following commodities: Die-casting, powdered metals, springs, stampings, injection molding and others. On-site support provided to suppliers in Mexico, USA, England and China. Improve supplier base performance.

Situation: High defect rate on stamping components causing severe production assembly problems and high rework costs. Responsible for coordinating supplier transfers in China and North America.

Action(s): Implemented quality improvement initiatives in die-casting, and powder metals. Collaborated with stamping suppliers to establish service level agreements and QI initiatives. Coordinated a team to manage supplier transfers in China and North America.

Result(s): 25% reduction in quality problems and an estimated savings to Trico of $200,000 per year from reduction in rework or warranty issues in several die casting, powder metals and stamping suppliers. Smooth supplier transfers in China and North America projects were implemented on time.

Supplier Quality Engineer, Ranco North America (Automotive water pumps and temperature control products) Oct 98 to Sep 02.

Responsibilities included: Overview the supplier quality engineering activities: supplier audits and development projects, PPAP training and approval, follow up component rejections and corrective actions.

Situation: Severe problems on assembly lines caused by screw-machined, stamping, plating and plastic components causing high scrap and downtime.

Action(s): Implemented improvement plans with suppliers to resolve severe customer quality rejections. Provided on-site support to suppliers; coordinating corrective actions implementation to guarantee resolution to customer and assembly lines problems.

Result(s): Solved major problems with plating, stamping, molding and screw machine suppliers through supplier certifications & development. Improvements performed to procedures for supplier quality activities. Earned an estimated savings to Invensys of 1.5 M in 4 years from reduction of downtime and scrap.

Production General Supervisor, Auto Trim de Mexico / Tex Mex Trim (Automatic shift knobs for Automotive Companies) April 1997 to Oct 1998:

Responsibilities included: Directed production supervisors, assistants, warehouse personnel, maintenance technicians, quality auditors and operators. Ensured on-time customer shipments. Continuous improvements implemented through effective analysis and techniques. QS-9000 coordinator. Training responsibility for all Plant personnel. Employee recruitment.

Situation: Assembly lines were being transferred from a plant in Matamoros, Mexico to Los Indios, Texas.

Action(s): Strategic employee recruitment and detail training plans implemented to ensure smooth transfer of operation.

Result(s): Successfully transferred assembly operations from Matamoros, Mx to Los Indios, Texas. Outstanding performance accomplished based on effective management and excellent environment focused on teamwork and motivation. Operation productivity increased 15%.

Incoming Inspection Supervisor, Allied Signal Automotive (Safety Restraints Systems)

Dec 1996 to Mar 1997:

Responsibilities included: Responsible for the Incoming Inspection activities, managing Quality Inspectors and Technicians to provide support to production lines.

Situation: Plant struggling to get certified components on time to keep production lines running.

Action(s): Implemented detail inspection plans for Inspectors and Technicians based on employee’s talent. Improved Incoming Inspection procedures working with plant engineers.

Result(s): Creation of departmental procedures that met QS 9000 with no findings on Plant Certification.

Effectively managed Incoming Inspection department.

Supplier Quality Assurance Engineer, Zenith Electronics Corporation (Electronic products for TVs) Feb 1994 to Nov 1996.

Responsibilities included: Responsible for the Incoming Inspection and supplier base activities: Supplier audit, certification and development; certification of components to production lines and reduction of rejections.

Situation: Plant suffering with constant rejections that caused high scrap and downtime.

Action(s): Implemented improvement programs to suppliers that were managed more effectively on-site. Implemented meetings between plant engineers and suppliers solved assembly problems.

Result(s): Improvements to components performance and reduction of total material rejected (average from 750k to 10k dlls) helped the elimination of Incoming Inspection Department.

Manufacturing Supervisor / Process Engineer, Deltronicos de Matamoros (Automotive Radios) Jun 1991 to Feb 1994.

Responsibilities included: Managed paint department with 40 operators and 4 technicians to meet production plans. Follow-up procedures to be in compliance with QS 9000 standards.

Situation: Paint department causing high downtime to production lines caused by not meeting production demands and poor quality of buttons.

Action(s): Improved production plans, provided training to operators and technicians. Reassigned personnel based on employee talents.

Result(s): Considerable scrap and machine downtime reductions based on process optimization in result of analysis and investigation performed to the process. Several cost reduction programs implemented.

Additional Training

Lead Auditor for ISO 9001 2015 Grupo IM-PROVE

BIQS General Motors

Black Belt Training Grupo Dextro

Lean Sigma Enterprises University of Texas

PPAP 4th edition training University of Texas

PFMEA training. University of Texas / TSC

SPC University of Texas

Internal Audit Certification University of Texas

Heat Treatment Quality on the Steel IMENDE

Global 8D Problem Solving Ford Motor Company

MRP (Manufacturing - Production) Invensys Controls

Paint Seminar Delco Electronics

Emergency Response SEDESOL / Delco Electronics

First Line Supervisor Delco Electronics

Synchronized Manufacturing Conference ITESM

SYSTEMS EXPERIENCE: Lean Manufacturing, Six Sigma, Lean Manufacturing, ISO/TS-16949, ISO 14001.

Just in Time, MRP and MRP II, Inventory Control,

SOFTWARE EXPERIENCE: Microsoft Office: Excel, Word, and PowerPoint. Acrobat

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