Project Engineer / Project Manager/ Operations Manager

RAFAEL MARCANO email: *********@*****.***

**** *** ********* 520-***-**** mobile

Mission, TX 785**-***-*** 0776 home

SUMMARIZED HIGHLIGHTS

• Change agent who has managed factory turnarounds in USA and abroad while successfully developing manufacturing strategies that support sector and division strategic plans while creating metric driven cultures.

• Fully bilingual: English / Spanish, degreed Electrical Engineer, with exceptional background in national and international multi-plant management. Multicultural experience.

• Worked hand in hand with product teams insuring design for manufacturing, for test and for quality are met prior and during New Product Introduction and sustained factory production.

• Ample experience in start ups and green fields for OEM and EMS businesses receiving customer and industry awards.

• Managed large product transfers from US and Canada to low cost geographies.

• Responsible for production sourcing decisions and site rationalization.

PROFESSIONAL BACKGROUND

4/10 – 12/2010 Vice President of Manufacturing

LGE, Reynosa, Tamaulipas, Mexico

Responsible for Manufacturing, Materials, Purchasing, Engineering, New Product Introduction and Outsourcing with total headcount of more than 2600 members and yearly sales of $3.2B USD. 31% increase in shipments while decreasing headcount by more than 60% and improving quality by 38%. OTD improved to 97% from less than 63% as operational efficiency increased by 26%. Worked with HR to improve VoE by 10% while reducing turnover by nearly 50%. Implemented 3 Days Frozen Schedule. New Product Introduction process improved by realigning organization and processes while still successfully introducing more than 100 new models in 5 months. Inventory reduced by 47% in 5 months by establishing a pro-active materials end-of-life team, materials sales back program, weekly raw material PO vs. demand process and reduced raw material lot sizes. Innovative and first in class manufacturing process established with worldwide savings of $8.3M USD. PCBA local sourcing increased by 25% resulting in yearly cost savings of $2.1M USD.

7/07 – 3/10 Vice President Operations

Sargent Controls & Aerospace, Tucson, Arizona

Responsible for all manufacturing operations. Led Lean transformation and turnaround of Mexico and Montreal facilities. Going “back to basics” and applying Lean techniques in 3 months increased productivity 11%, increased production output by 18%, revenue by 9.8%, shipments by 6%. Reduced duties into Mexico by 61%, tooling cost by 52%, doubled First Article acceptance rate and reduced past dues by 38%. Factory out of the red in 6 months. Opened 24% green space that has allowed site to accept new customers & new business. Revamped new product process while introducing more than 55 new products in one quarter. Transit time to and from the border reduced by 75%. Freight costs have been reduced in excess of 50%. In Montreal, reduced past due orders 86% while eliminating customer quality complaints. Manpower aligned to business size while increasing employee commitment and union support. New Product Introduction process aligned with customer needs and delivery requirements. Successfully implemented DuPont’s STOP safety program across corporation resulting in 65% reduction in recordable accidents and $175K in workman compensation savings. Established standard KPI’s for all manufacturing operations achieving a 38% reduction in scrap, 12% improvement on delivery, 26% reduction in past due. Actively participated in potential acquisitions leading the operations and EHS teams in the due diligence process.

7/01 – 6/07 General Manager

Celestica Aerospace Technology Corporation, Austin, Texas (4/05- 6/07)

Full P&L responsibility. Led transformation from commercial to Aerospace and Defense manufacturing. Successfully exited customers that did not meet desired profile in alignment with sector strategic plans. Managed to break even with revenue shortcoming of 22% for 2005 while achieving profit plan in 2006 with a 10% revenue shortcoming. Drove Lean and 6 Sigma resulting in 1.6% of Sales cost reduction. Reduced factory space utilization by 37%, increased productivity by 43%, cost reduced by 24% & improved operational effectiveness by 46%. Improved Working Capital through increased equipment utilization and improved Inventory Turns from 5.8 to 8.2. Established Bid Proposal Team that lead to the multiple awards of new non-organic A&D business. New ERP system implemented in 12 weeks. Supported other Celestica sites as they entered into Aerospace market. Managed factory capital expenditure programs to align business and technology offering with customer roadmaps and business needs. Received 3 Raytheon Supplier of the Year awards from more than 1000 suppliers, and Sullivan and Frost award for best performing EMS serving the Aerospace & Defense Industry, recognized as Most Improved Site in 2006 and received CEO award for Cost Reduction and Operational Effectiveness. Security clearance: Secret.

Director, Global Business Operations, Celestica, Inc. (5/02 – 3/05)

Austin, Texas

Member of Global Customer Unit responsible for new and emerging accounts in North America. Responsible for $200M P&L. Managing 2 multi-sites, multi technology customers working with multiple sites in different geographical regions. Responsible for site selection and sourcing decisions. Transfers into low cost country (China) resulted in $10M savings to customer and increased profitability. Worked with local Chinese teams (2 sites) to accelerate transfers resulting in increased business, sole source position and increased customer satisfaction. Transferred Power Supplies and Power Amplifiers from US and Canada to Donguan and Suzhou, China. Negotiated with customer to cover all transfer cost resulting in more than $1M in unplanned revenue. Raw material shared between sites to insure lowest TCOO. Achieved highest customer satisfaction rating & received Supplier of the Year Award for 2004.

Director of Integration, Celestica, Inc. (7/01 - 4/02)

Celestica Inc., Monterrey, Mexico

Managed virtual multi-site, multi-geography team in largest product transfer in company history. Seven sites involved, as well as, 2 customer sites and 3 competitors. Multiple technologies and customer divisions involved in transfers. Worked with corporate functional teams to insure execution to customer expectations. High level of customer satisfaction achieved through transfer as quality and cost goals were met or exceeded. Revenue increased due to transfer $1.4B.

2/92 - 6/01 Director of Manufacturing Operations & Site General Manager (4/00 - 6/01)

Motorola, Inc. Chihuahua, Mexico

Led transition from paging to cellular factory. Installed 6 double-sided SMT lines. Transformed site into most cost effective factory surpassing China resulting in $62M cost savings. Worked with Mexico SECOFI (Ministry of International Commerce) insuring $0 duties for raw material importation. First year savings exceeded $21M. Distributed 1st product directly from the Chihuahua facility into the Mexican market resulting in savings of $24M/year. Established fastest new product ramp up in group history. Achieved 45% cost reduction in first 6 months of 2001 while reducing inventory by 33%. Quality improved 67%. ISO14000 certification. Site 2000 sales $800M. Site 2001 sales run-rate $1.2B.

Director of Technology and Strategy Programs, EMEA (1/00 - 3/00)

PCS, Motorola, Inc., Dublin, Ireland

Developed Manufacturing Technology Strategy that would double EMEA’s cellular capacity while providing leading edge technologies that would provide competitive advantage. Directed virtual multicultural team assigned to reduce test cycle times by 50%. Assigned teams by product protocol technology and product type. Leads in 3 major geographies were selected and baselines established. Reductions and lessons learned were shared. Cycle time reductions exceeded goal and cost avoidance resulted in capital avoidance of $70M.

Director of Manufacturing Operations & Site Manager (8/98 - 12/99)

Motorola, Inc., Boynton Beach, FL

Asked to relocate to Florida to reduce cost and transition of organization. Responsible for high-volume, high-mix factory. Managed Production, Supply Chain, Manufacturing Engineering and Advanced Manufacturing Technologies. Achieved 49% reduction in conversion cost and 15% reduction in operational budget. Transitioned factory from high-volume, high-mix to low-volume, high-mix manufacturing, technology development and new product introduction site. Managed $19M budget. Site sales $400M.

Site General Manager (1/98 - 7/98)

Motorola de Mexico, SA, Chihuahua, Mexico

Achieved fastest ramp in Paging history. New monthly production and shipping records established for 7 consecutive months resulting in$20.4M savings. Established direct fulfillment to Mexican market, reducing cycle time by more than 2 weeks and increasing customer satisfaction. Achieved lowest cost of any Paging facility in the world. Managed $11M budget. Site sales $250M.

Manufacturing Operations Manager & Materials Manager (2/96 - 12/97)

Motorola de Mexico, SA, Chihuahua, Mexico

One of two expat’s in new $75M facility. Developed site’s master start up plan. Output increased 83% and quality goals met. Product transferred resulted in 50% cost reduction. Inbound and outbound logistics routes were established, warehouse in El Paso, TX was contracted, NAFTA certification was obtained and international and domestic shipments started. Established Traffic and Customs office, Purchasing and Planning department, as well as, Shipping, Packaging, Warehouse and Receiving departments.

Operations Manager (11/94 - 1/96)

Motorola, Inc., Boynton Beach, FL

Factory had not achieved ship acceptance in 2 years and was in the red. Went “back to basics” doing Value Stream Mapping, time studies, eliminating bottlenecks, training engineers and supervisors. 68% quality improvement achieved and was out of the red in 9 months. Improvements resulted in cost savings of $14M.

Motorola, Inc., Vega Baja, PR (2/92 - 10/94)

First Material Quality Engineer. Promoted to Product, Process and Equipment Engineering Group Leader, Section Manager and Production Manager for low-volume, high-mix programs.

5/89 - 12/91 Sippican, Co., Marion, MA

QA, Test and Safety Engineer Responsible to insure product met USA and Australian Navy requirements. Developed final product acceptance test and systems complied with MIL-Q-9858A and MIL-I-45208.

Security Clearance: Secret

1/86 - 5/89 Raytheon Co., Waltham, MA

QC and Test Engineer Reduced cycle time by 59% and defects by 87%. Achieved cost savings of $1.4M/year.

Security Clearance: Confidential

ACADEMIC BACKGROUND

BS Electrical Engineering, Boston University 1986

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