Lean Manager
Resume:
Carlos Scholz Moreno
**** ******** **, ******* **, 11510
******.******@*****.***
Innovative, focused and results driven leader focused on achieving exceptional results in existing or start up operation organizations through continuous improvement, best practices, benchmarking and organizational development. Experienced in driving product, processes, customer service improvements while optimizing overall supply chain performance and supporting human resources development through the organization. Proven performance and experienced across multicultural environments (North America, Latin America, China).
CORE COMPETENCIES:
Process Optimization through Lean and Six Sigma, Project Management and Execution, Operations Management, Operational and Strategic Planning, Budgeting, Supply Chain Management, Organization Development, Start up scenarios, Process Engineering, Quality Management.
EXPERIENCE
D’ADDARIO & COMPANY, Inc
Senior Quality Assurance & Process Engineering Manager
(Current since July 2007)
Achievements: Strong performance and operational improvements in First Pass Yield, Defects per Million Opportunities (dpmo), customer and consumer returns, and Cost Reductions through Continuous Improvement Implementation. Planning and execution of major projects included leading and implementing the D’Addario Quality Management System, successfully training and executing the foundation of the system at all levels of the organization, develop all the documentation for the company, lead internal audits, corrective actions and preventive actions. Through the use of Continuous Improvement tools, such as 8D’s, A3, SPC, Standardized Work, SMED, TPM, I lead and facilitated more than 30 Rapid Improvement Events, all focused entirely on Problem Solving activities to improve quality, reduce waste and improve customer service in the organization. Developed and lead the implementation of Quality Control Reporting Systems for all the areas of the organization. Quality at the Source and new Quality Controls, including the elimination of unnecessary inspections, while keeping better quality results played a major role in changing the organization’s culture, to focus more on quality. Results of projects implemented yielded more than $3 MM total, which included reduction of scrap, rejects, quality improvements, elimination of unnecessary quality checks, implementation of new automated equipment, etc.
Scope of responsibilities: Responsible for controlling quality control and process engineering for all of the organizations processes, including string manufacturing (fretted and bowed), drum heads manufacturing, reeds manufacturing, and other music utilities (cables, straps, guitar picks, tuners, and hundreds of accessories) including other subsidiaries and joint ventures for wire manufacturing, as well as overseeing the quality for all outsourced products in China. Total workforce totaled about 1,100 associates, who support just over $135MM in sales per year. The Quality Control group was formed by more than 40 associates across all areas of the organization, including Quality Managers, Quality Engineers, Inspectors and musicians.
HANESBRANDS, Inc.
Operations and Lean Manager
(2006 -2007)
Achievements: Lead and implemented Lean and ISO initiatives in a startup operation that included Knitting, Finishing and Cutting of circular knit fabric for underwear garments. Improved productivity, process cycle times, product flow, quality and inventory levels through Continuous Improvement. Major projects implemented included the facilitation of more than 35 Rapid Improvement Events across all production areas, that yielded inventory reduction from 4 weeks to 2 days for WIP, 3 months to 1 month in Raw Materials, for a total of just over $1.5MM in total inventory reduction; Productivity Levels that increased the number of parts per operator per hour by more than 30% and Quality Defects reduction of more than 40%, all while keeping a service level of 95% or higher. Cost savings in excess of $5MM helped improve the cost of production by 25%.
Scope of responsibilities: In charge of the Operations of the new startup facility in Bonao, Dominican Republic, which represented a major manufacturing re-configuration for circular knit production from the USA to the Dominican Republic. Production represented more than 3 million lbs of fabric per month. Total number of associates ranged in the 1,500. Operation Management included control over Production, Maintenance, Engineering, Quality and Production Scheduling.
HANESBRANDS, Inc
Lean Manufacturing Manager
(2005-2006)
Achievements: Lead the implementation of Lean Manufacturing Practices in a multi-facility environment, that included Cutting, Sewing and Distribution Operations for intimates apparel and underwear.. Major projects implemented included the facilitation of more than 20 Rapid Improvement Events across all facilities, that yielded inventory reduction of just over $3MM in total WIP, Raw Materials and mostly Finished Goods, which at the same time helped improve Customer Service Levels from the Low 90’s to the High 90’s; helped consolidate sewing operations into manufacturing cells, using standardized work principles that yielded in productivity improvements of more than 25%, Improved production flow and flexibility in the cutting and molding departments that allowed the increase of product mix and reduced volume levels through SMED and initiated the consolidation of cutting and sewing value streams by product families. Cost Savings represented more than $1MM.
Scope of responsibilities: In charge of the Lean Implementation for 3 manufacturing facilities in Mexico, including Cutting and Sewing operation of intimate apparel and underwear garments, as well as 2 distribution centers in Mexico City. Production represented more than 1 million units produced per month and total number of associates ranged in the 1,500. Worked along with Production, Planning, HR, Maintenance, Engineering, Product Development and Distribution to successfully implement Rapid Improvement Events.
HANESBRANDS, Inc
Process Improvement Engineer
(2002 - 2005)
Achievements: Lead the implementation of Lean Manufacturing and ISO Practices in a sewing facility in Mexico. Major projects implemented included the facilitation of more than 35 Rapid Improvement Events across all processes, that yielded inventory reduction of just over $500M in total WIP, and Raw Materials, all while improving Customer Service Levels from the Low 90’s to the High 90’s; helped consolidate sewing operations into manufacturing cells, using standardized work principles that yielded in productivity improvements of more than 25%, Implemented ISO practices that helped the facility get ISO certified. Cost Savings represented more than $1MM.
Scope of responsibilities: In charge of the Lean and ISO implementation for 1 sewing facility in Mexico for intimate apparel manufacturing. Production represented more than 750K units produced per month and total number of associates ranged in the 800. Worked along with Production, Planning, HR, Maintenance, Engineering, Product Development and Distribution to successfully implement Rapid Improvement Events. Some projects included a wider scope, and I participated in Lean Events for the Central America Region, including Sewing facilities in El Salvador, Costa Rica and Honduras.
EDUCATION
Instituto de Estudios Superiores de Tamaulipas (IEST)
Bachelor of Science
Industrial and Systems Engineering
From 1997 to 2002
MAGNA CUM LAUDE
PROFICIENCY:
Software: Microsoft Office (Outlook, Project, Visio, Word, Powerpoint, Excel, Access), MRP systems, AS/400.
Language: English and Spanish
OTHER TRAININGS AND CERTIFICATIONS:
Lean Manufacturing
Six Sigma Green Belt
Train the Trainer
GSD (General Sewing Data)
Project Management
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