AGUINALDO MATZENBACHER • Green Card Holder

Senior Director of Manufacturing Operations & Lean expertise

Toledo, OH • +1-463-***-**** • adwf7k@r.postjobfree.com • https://www.linkedin.com/in/aguinaldo-matzenbacher

Extensive success managing multi-site large P&L with a hands-on approach, improving operational efficiency by progressive leadership experience in Lean Manufacturing principles. Recognized by strong commercial focus on the customer and end user experience by leading, developing, and inspiring teams to establish a high-performance work culture and growth vision.

Multicultural experience acquired during expatriation contracts in China, the US, Mx, and S. America.

WORK EXPERIENCE

SERAPH, Michigan, MI Jul 2022 – Present

Senior Business Process Management Consultant · Self-employed

Supported clients to improve Industrial Performance results through turnaround strategies based on Lean Manufacturing. Improved production output by 17% within 3 weeks.

Deployed Lean Manufacturing principles and improved production output in 32% within 3 weeks in a medical technology facility including main suppliers with capacity issues.

Implemented production control business KPIs within 2 weeks to create transparency for executive management level, decision-making and action plan implementation.

FORVIA/Faurecia, Toledo, Ohio Feb 2021 – Jul 2022

General Plant Director – reporting to VP operations.

Deliver insightful leadership to steer three OEM account management (Ford, GM, and Stellantis) while managing annual sales of $200M. Leverage strong communication skills to ensure coordination, influence, and engaging in an ethical way the contract negotiation with the local labor union.

Developed an annual budget of $200M sales and expense forecast by mentoring 10+ Managers.

Developed business strategy deployment, deployed staff targets enhancing safety culture: Zero event for 3 years - EHS, maximize Product Quality, and on-time deliveries.

Reduced absenteeism from 19% to 7% with proven track record.

Improved customer satisfaction score and product quality by 55% within 4 months.

Improved Gross Margin on 3% higher than annual budget throughout P&L Management, cost analysis, diagnosing potential root causes and analyzing data on staff effectiveness.

P&L management achieved cost avoidance of $420K in CAPEX Manufacturing Engineering.

Accomplished $1M (-20%) warehouse inventory mgmt. through lean manufacturing principles.

Deployed Lean Manufacturing Excellence System principles including daily management business metrics KPIs, and agenda to review problem-solving.

Achieved 27% decrease in breakdowns executing excellence business intelligence (BI) and using technical expertise with Paretos comparing with best practices.

Achieved 52% scrap reduction throughout Six Sigma teams defining business improvements.

FORVIA/Faurecia, Columbus, IN Mar 2020 - Apr 2021

Director of Program Management – reporting to CBU VP and Programs VP

Led and managed 13 programs following automotive APQP prioritizing tasks for Ford CBU with annual sales of $367M. Ensured successful execution of respective programs by validating business plans. Maintained knowledge of the financial tool (TM1), and the consolidation of financials - program in business development.

Drove improvement on IBP at 0.5% in OI points, representing a $1.3M uplift in OI with 4 of the IBP’s published in S2 (2020).

Improved Work Package delivery, from 56% to 100%, by cross-functional global manufacturing teams leadership and streamlining project management skills since acquisition.

FORVIA/Faurecia, Columbus, IN Jun 2018 – Mar2020

Senior Director of Manufacturing Operations – Commercial Vehicles - reporting to CBU VP and Ops VP

Provided oversight of multi-site management for commercial vehicles across two plants with 642 employees and sales of U$460M. Identified and filled gaps to enhance budgeting operational leadership performance by executing optimal processes.

Budget development and P&L management of $460 million sales, resulting in a 25% increase in revenue and 5% cost savings through quality and process improvement, manufacturing operational initiatives using Value Process Mapping and line design improvements to uplift production.

Leadership coaching and reinvigoration of Hoshin Kanri and Monthly Operations Review.

Implemented plant management standardization, standard work audits and huddles reviews.

Gave strategic direction comprising 3 years plan with P&L focus and process improvement.

Deployed goals for +13 managers linked with lean concept application and significant change management to effectively reduce cycle-time on specific and across value stream processes.

Improved product and manufacturing operations process quality throughout Six Sigma teams and lean methodologies defining improvements in TPM, product design, process improvements, management systems, Manufacturing Operations, Healthy, Safety and Environment during the tooling reengineering.

Coordinate industry 4.0 implementation Global Project Management across 12 plants within US and Mexico perimeter (comprising a total of U$ 2,8Bi in P&L) with a prime emphasis on interconnectivity, automation, machine learning, and real-time data. Nine smart robots deployed, AGVs, and SRS system.

FORVIA/Faurecia, Santa Fe, Mexico – Seating division Sep 2015 - Jun 2018

Reg/Div. Mexico Quality & HSE Director (Senior Director of Manufacturing for a year)

P&L management for multi-Site with 1,300 Employees and U$720M of sales. Established a safe, healthy, and hygienic environment across 5 factories and R&D by adhering to EHS standards. Successfully coordinate certification on Formel Q, ISO, TS16949, SGA, QSB, CCC, and ISO14001.

Improved business operations Direct Labor on 3% of sales driving the teams for continuous improvement performance of Manufacturing throughout Hoshin and Kaizen workshops.

Directed successful introduction of 7 new lines for VW/Audi new business launch.

Drove 27% decrease in suppliers’ defects by employing quality best practices.

Created, tracked, and accomplished strategic goals by attaining SMART objectives.

Directed customer quality, quality operations, and program quality teams for 5 plants within Mexico perimeter with a total employee base of 4,900 employees.

Evaluated and enhanced quality of 17 programs by implementing effective QA policies and practices.

FORVIA/Faurecia, Cottondale, AL Aug 2013 - Jul 2015

Div/Reg Customer Director - Mercedes Benz and BMW - USA

Acted as a primary interface for Mercedes Benz and BMW customers.

Improved customer satisfaction from 56% to 85% with delivery performance exceeding 95% satisfaction. Decreased NQ Cost by 54% and PPM (parts per million) from 180 to 17.

FORVIA/Faurecia, Quatro Barras, Brazil Jan 2011 - Aug 2013

Reg/Div. Q Operations – Seating Division

Carried out self-assessments to streamline operational and programmatic processes. Acted as an In-charge to efficiently manage quality issues at 6 factories in Brazil, Argentine and Uruguay.

Reduced PPM from 230 to 53 and 45% customer satisfaction increase.

NQC reduced by two while mapping and stabilizing the quality team personnel. Introduced quality tools concepts, problem solving, QRCI, FMEA, and SPC.

Robert BOSCH, Curitba - Brazil Jan 2007 - Dec 2010

Operations Lean Manager

Executed process orientation management on support processes while serving as a Management System Assessor:

Improved profitability OI on 13,6% implementing Lean Excellence Manufacturing Engineering on main and support processes.

Provided overall Lean leadership and simplification to key areas of supply chain and services.

Implementation and facilitation of significant impact by spearheading initiatives such as 5 S, TPM, standardized work, Kanban, quality tools, production leveling, SMED, Value Stream Mapping & Management, push to pull system and digital solutions.

Robert BOSCH, Suzhou - China October 2002 - Dec 2006

Production Manager / Quality Manager

Experience in production start-up acquired during implantation of two new factories with electronic clean room manufacturing grade compliance at Suzhou city - China.

Project manager in charge of electronic components and mechanical components lines transference from Australia, France, and Germany to China site.

Robert BOSCH, Curitiba – Brazil • SPC specialist / Supervisor /Planner April 1991 - Sep 2002

LANGUAGES:

Portuguese – mother language / English – fluent / Spanish – advanced

EDUCATION

Ignite Business Program, London Business School

MBA in Strategic Management of Enterprises, FGV/ISAE Getulio Vargas Foundation

Graduation, Business Administration, University Business School FAE

Skills: Coaching, Leadership Development, Integrity, Positive, Flexibility, Collaboration, Mentor others, Organizational Development, Ability to lead and train, People Development, Credible, Innovator, Consistent, Problem Solve, Conflict resolution, Self-motivation, Humility, Excellent Communications, Excellent interpersonal skills.

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