Lean Master & Lean Management Coach
Supporting and leading Leader Standard Work transformation at several upstream oil- producing sites.
Deploying LSW as the lean management system for the operations and maintenance value stream.
Coaching and mentoring leaders, from top – down, into making the transition from managers-to-leaders acting as coaches & facilitators, under the servant leadership model.
Achieving LSW by practicing its five main components: diary -> weekly one-to-one -> connected / escalated checking -> continuous improvement -> reconnects.
Developing of the teams through coaching, mentoring and knowledge sharing at all levels.
Merck & Co. / Tunnell Consulting, Inc. (Contractor). US
Senior Lean Consultant – Toyota Kata Coach
Supporting and leading Toyota Kata deployment at Merck.
Coaching learners in the four-step improvement kata. Mentoring coaches in the coaching kata techniques.
Teaching the Toyota kata methodology through boot camp training.
Acting as learner, coach, second coach, and master coach throughout the deployment.
Developing of the learners and coaches to attain competent or higher levels of skill.
Responsible for the transfer of knowledge to learners and coaches.
Johnson & Johnson, Valumetrix Services, Ortho Clinical Diagnostics. US, Worldwide
Lean Consultant – Master Black Belt
Lean Consultant for Valumetrix Services, a healthcare consulting group of Ortho Clinical Diagnostics, a Johnson and Johnson Company.
Led lean transformation projects at hospitals' laboratories and histology reference labs.
Achieved overall process improvements of: 35% TAT, 25% defect reduction, 20% headcount realignment, 25% space reduction, 30% inventory reduction.
Responsible for the transfer of knowledge of the team, management, staff, and executives so they can continue improving and sustaining the gains.
Led assessments in radiology, laboratories, and catheter labs. Also familiar with other departments such as pharmacy, OR, admissions, ED.
Led kaizen events in laboratories supporting the sale efforts of Ortho’s instruments.
Conducted lean speaking engagements at the Congress of the Mexican College of Pathologists and have filmed lean lectures for professional distant education worldwide.
Worked internationally with clients in Canada, Australia, Mexico and Chile.
Instrumental in the closing of new business opportunities and project’s up sales.
Honeywell Video Systems. US
Manager of Operations
Led the operations of the configuration center for the security video systems group.
Manufacturing and configuring security video products for eight different product lines.
Developed a highly flexible, cross-trained, manufacturing team capable of producing on a build to order fashion every day.
Responsible for the safety, quality, and production of the operation.
Working in a highly matrixed organization interacting with product line managers, customer service, sales and technical field departments as well as with suppliers and customers.
Responsible for developing, and for positively executing an annual operating plan.
Achieved $1M in cost savings during recent product line transfer.
Achieving further improvements by executing kaizen events and implementing a lean culture.
Johnson & Johnson, Cordis Corporation. US
Lean Six Sigma Master Black Belt
Responsible for the developing and deployment of the Process Excellence implementation plan. Created necessary processes to manage the implementation.
Accountable for achievement of plan. Have met and exceeded department’s cost savings and certification goals. Program’s status presentations to senior staff.
Institutionalized weekly evaluation meetings with the site’s leadership team and belt’s supervisors to review status of projects, certifications, and overall progress & barriers.
Responsible for the training, mentoring, coaching & certification of green, black belts & MBBs.
Achieved 100% certification and re-certification of belts within 2 years of program start.
Have closed more than 100 projects, from full scale to quick projects, achieving more than $10 MM in annualized savings validated by the finance department.
Involved a finance partner dedicated to validate and monitor cost savings on a monthly, quarterly, and yearly basis. All official savings reports provided by finance partner.
Participated and presented in monthly worldwide process excellence meetings.
Teaming with, and training of upper staff in the identification of new opportunities.
AlliedSignal, Inc. (Now Honeywell). US, Latin America
Lean Six Sigma Implementation Leader
Implemented lean mfg. & six sigma for this automotive safety restraints plant. U-shaped cells, one-piece flow, set-up times reduction, Kanban, TPM, etc. Improvements achieved include:
Space reduction of 33%, headcount reduction of 10%, cycle time reduction of 25%, inventory reduction of 15% ($1.3 MM), Set-up time reduction 70%, productivity 25%.
Due to inventory and space reduction initiatives a 50,000 square feet warehouse was emptied, and relocated to a manufacturing building where 29,000 square feet were obtained resulting in annual savings of $200,000.
Redesigning current warehouse operations by using special floor racks, point of use storage and grocery store area contributing to above mentioned annual savings.
Obtained Black Belt certification on 1/1997 and Green Belt certification on 11/1996.
Participated in an on-site supplier development program. Visited several local suppliers to evaluate, improve their overall performance in quality, delivery, and cost.
Alcoa Fujikura Ltd. US, Latin America
Senior Manufacturing Engineer
· Oversaw the engineering of automotive wire harness assembly at four 100,000 square feet, 700 employee plants. Responsible for the advanced manufacturing aspects for 650,000 vehicles annually using 20 wire assemblies per vehicle.
· Served as liaison amongst, and traveled to company plants, design offices and customer plants to incorporate design changes and resolved any concerns.
· Prior to a new model year, allocate tooling, equipment and resources to prepare for production start-up. Analyzed manufacturing feasibility for cost saving opportunities.
Senior Engineering Liaison
· Transferred to this client's plant and served as liaison between the company and the customer on a variety of issues from quality standards to resolving supplier conflicts.
· Trained an inspection team at the customer's location resulting in a 50% decrease in manufacturing rejections.
· Gained experience in Ford's Quality System. Instrumental in the plant receiving Ford's Quality Award (Q1).
Joely Industries. US
Production Manager
· Led close to 200 people: supervisors, lead persons and operators involved in the manufacturing of electronic computer cables. Set up and balanced assembly lines for scheduled weekly jobs.
Outboard Marine Corporation. US, Latin America
Manufacturing Engineer
· Developed and implemented complete assembly processes for new and transferred lines, and updated existing ones for this outboard engine and parts manufacturer.
Production Supervisor
· Supervised 5 group leaders and 90 operators assembling components for outboard engines; remote controls, fuel pumps, junction boxes.