Summary
Overview
Work History
Education
Skills
Timeline
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Alex Chaib

The Woodlands,TX

Summary

Strong and extensive experience in plant management, materials control, scheduling, forecasting distribution/warehousing, and inventory control. Skilled in Lean Manufacturing and Corrective Actions, and Root Cause analysis for problem solving. Intense focus on Continuous Improvement. I am results oriented, customer focused, and customer driven. I have extensive experience in both high volume and low volume build to order manufacturing. I am fully bilingual, can speak, write, and read Spanish fluently.

Overview

39
39
years of professional experience

Work History

Supply Chain Manager

National Wire
Conroe, TX
04.2025 - 08.2025
  • Oversee all raw material and purchase part procurement.
  • Manage all raw material, WIP, MRO, and finished goods inventories.
  • Led all Cycle counts processes and subsequent adjustments in inventory.
  • Coordinated all inbound and outbound freight.
  • Oversaw the freight quotes and lane assignments.
  • Oversaw all production scheduling and planning based on customer requirements.
  • Managed all manufacturing replenishments to maintain operations at an optimal level.
  • Oversaw all mobile equipment safety programs and incident investigations.
  • Oversaw customer issues and delivery problems.
  • Developed and tracked Supply Chain KPI’s, and their monthly reviews.
  • Led the weekly S&OP meeting with Sales and Production.
  • Improved the S&OP process by analyzing sales forecast and inventory levels.
  • Achieved a 10% cost reduce on freight costs.
  • Increased stock item availability to 91%
  • Improved inventory accuracy to 98.9 %
  • Conducted data analysis to identify operation bottlenecks and eliminated them.
  • Improved OTD to over 98% to improve customer satisfaction.

Production Control Manager

Reyes Automotive
San Antonio, TX
02.2024 - 03.2025
  • Oversee all the materials planning, inventory control, part number sequencing, and logistics for the multi-plant company that supplies the Toyota and Tesla.
  • Manage a team of over 100 materials and logistics associates that work in 3 shifts 7 days a week operation.
  • Keep an accurate record of all inventory parts.
  • PFEP management.
  • MRP responsibilities in production scheduling and assuring proper back flush processes.
  • Responsible for procurement and supplier releases.
  • Coordinate all inbound and outbound freight, which includes rail, trucks, and oversea containers.
  • Manage all manufacturing forecasts and plan scheduling of the facilities.
  • Manage all inventory control levels and ensure proper warehousing processes.
  • Assure that all obsolescence was kept to a minimum.
  • Work with the customer and our production teams to properly identify, report, and record all scrap.
  • Constantly assured that all safety procedures were being followed and all incidents had the proper 8D and corrective action plans.
  • Assure Lean Manufacturing processes for materials replenishment and on Kanban lines to keep inventory on time, right parts, and right quantities, and reduce and eliminate production down-time and increase cycle times.
  • Control all proper Min/Max warehousing processes.
  • Assure that proper counts and inventory adjustments were being made to maintain inventory accuracy.
  • Control all production schedules and on time customer release deliveries.
  • Maintain a JIT program for a 1,000 vehicle per day production schedule of large SUV, Tundra, Tacoma units for Toyota.

Materials Management Consultant

AST Space Mobile
Odessa, TX
05.2023 - 12.2023
  • Develop all the materials planning, inventory control, part number sequencing, and logistics for the multi-plant operation.
  • Establish material processes in this aerospace start-up.
  • Created Line-Side inventory locations to quickly replenish manufacturing work orders.
  • Establish a receiving and shipping process and procedure, in SOP.
  • Create and organize a warehouse inventory system to store and manage all inventory.
  • Created a cycle count program.
  • Created a Kanban process for all consumables.
  • Keep an accurate record of all inventory parts.
  • Assure manufacturing operations are replenished with production parts on a timely just in time basis during the 3-shift operation.
  • PFEP management.
  • MRP responsibilities in production scheduling and assuring proper back flush processes.
  • Coordinate all inbound and outbound freight, which includes rail, trucks, and oversea containers.
  • Establish inventory control levels and ensure proper warehousing processes.
  • Assure that all obsolescence was kept to a minimum.
  • Work with the customer and our production teams to properly identify, report, and record all scrap.
  • Constantly assured that all safety procedures were being followed and all incidents had the proper 8D and corrective action plans.
  • Assure Lean Manufacturing processes for materials replenishment and on Kanban lines to keep inventory on time, right parts, and right quantities, and reduce and eliminate production down-time and increase cycle times.
  • Control all proper Min/Max warehousing processes.
  • Assure that proper counts and inventory adjustments were being made to maintain inventory accuracy.
  • Establish a weekly coordination meeting with manufacturing, quality control, procurement, production scheduling, and materials to understand current and future requirements, and prepare to cover these manufacturing demands.

Distribution and Logistics Manager

The Jamco Group
Laredo, Texas
08.2020 - 05.2023
  • Dedicated to warehousing, fulfillment, and logistics of raw material and finished products.
  • Facilitated all warehouse picking to complete all customer orders in a timely and accurate manner.
  • Manage two distribution warehouses, 550,000 square feet and 200,000 square feet facilities.
  • Create detailed daily associate work performance efficiencies and track them to motivate improvements in work performance.
  • Created Lean Manufacturing policies to improve daily performance and metrics.
  • Coordinate Outbound truck load shipments of 90 per day and Inbound receiving at a daily rate of 80 trucks.
  • Coordinate cross border and north bound logistics to meet customer demand and requirements.
  • Executed a close working relationship and coordinated complex metrics with our customers.
  • Responsible for managing area warehouse and logistics supervisors, Account Customers Service Representatives, and warehouse associates manage their activities; coordinating of material flow; and support of customer service levels by developing, implementing, and maintaining logistics/ warehousing practices.
  • Synchronized the corporate logistics/ distribution/warehouse functions in compliance with policies and procedures to ensure achievement of key performance indicators.
  • Coordinate the movement of all materials to, from, and within each facility which includes accounting for incoming international transportation deliveries.
  • Collaborate with various departments; operations, accounting, customer service, or supply chain, to develop or revise plans, policies, and procedures for maximum utilization of logistical or material handling support.
  • Controlled inventory management activities including receiving, storing, rotating, handling, and shipping products within each distribution center.
  • Establish strict daily Cycle Count processes to improve inventory accuracy and effectiveness.
  • Continuously improve processes, statistics/analytics, reporting, and inventory systems which support efficient inventory control and optimal performance for the company.
  • Ensure optimization of warehouse space; warehousing is not hampered by poor housekeeping; supplies and parts are properly stored; and warehouse is maintained in an organized condition, free from clutter, and within the expectations of the company.
  • Achieved a strict 5S process throughout the various facilities.
  • Created Root Cause Analysis and Corrective Action processes to maintain a Continuous Improvement process.
  • Ensure full compliance of policies for handling obsolescence, physical inventory, and cycle counts. Conduct analysis and develop recommendations on various logistical and warehouse strategies that involve complex cost/benefit tradeoffs.
  • Responsible for facilitating daily activities across the Jamco warehouse network to ensure issues, such as operational, administrative, quality, and safety, are identified and addressed in a timely manner.
  • Established a shelf system fulfillment operation to increase order picking productivity and increase our available warehouse inventory locations; we went from 916 inventory locations to a total of 2,056 warehouse locations. This was an increase of 124 %.
  • Increase the quantity and volume of total number of customer orders and packages processed and shipped on a weekly basis. Prior weekly shipping average was 1,121 orders and 1,623 total packages, with Lean Manufacturing techniques; these weekly volumes doubled to 2,489 customer orders and 3,251 total packages shipped per week. This was an increase of 122 % in orders and 100% in packages processed per week.
  • Increased inventory accuracy and bin reliability to increase fulfillment productivity and order accuracy, from an initial 89.5 % to a high of 99.1 %.
  • Assure a Cycle Count program to improve inventory and financial accuracy of our inventory.
  • Overall shipping accuracy for customer deliveries is over 99.98 %, this critical metric was never tracked before.
  • Established disciplined order processing systems where there is direct accountability of the order picker and his order accuracy and customer satisfaction.

Production Control and Logistics Manager

Android Industries, LLC
Arlington, TX
01.2014 - 08.2020
  • Oversee all the materials planning, inventory control, part number sequencing, and logistics for the multi-plant Arlington company campus that supplies the General Motors Arlington plant.
  • Manage a team of over 100 materials and logistics associates that work in 3 shifts 7 days a week operation.
  • Keep an accurate record of all inventory parts.
  • PFEP management.
  • MRP responsibilities in production scheduling and assuring proper back flush processes.
  • Responsible for procurement and supplier releases.
  • Coordinate all inbound and outbound freight, which includes rail, trucks, and oversea containers.
  • Manage all manufacturing forecasts and plan scheduling of the facilities.
  • Manage all inventory control levels and ensure proper warehousing processes.
  • Assure that all obsolescence was kept to a minimum.
  • Work with the customer and our production teams to properly identify, report, and record all scrap.
  • Constantly assured that all safety procedures were being followed and all incidents had the proper 8D and corrective action plans.
  • Assure Lean Manufacturing processes for materials replenishment and on Kanban lines to keep inventory on time, right parts, and right quantities, and reduce and eliminate production down-time and increase cycle times.
  • Control all proper Min/Max warehousing processes.
  • Assure that proper counts and inventory adjustments were being made to maintain inventory accuracy.
  • Control all production schedules and on time customer release deliveries.
  • Maintain a JIT program for a 1,245 vehicle per day production schedule of large SUV units for GM.
  • Increased receiving efficiency and productivity, which reflected in a manpower reduction from 20 team members to 10 team members.
  • Reduced mobile equipment accidents from 55 in 2015 to 23 total incidents by the end of 2018.
  • Reduced Min/Max violations from 39 a month to less than 5 a month.
  • Successful model year Buildouts with no need for expedited freight and obsolescence.
  • Maintain a successful JIT process to keep the General Assembly running 24/7.
  • Shipped all vital components for Tahoe, Suburban, Escalade, and Yukon SUVs in the exact sequence these components were being assembled in the manufacturing line at GM.
  • Increased time unload and reload process in the receiving area with less team members.
  • Eliminated all detention charges due to timely receiving process.

Distribution Center Manager

The Toro Company
El Paso, TX
01.2007 - 01.2014
  • Responsible for the over 500,000 sq. ft. distribution center
  • Complete P&L responsibility
  • In charge of the facility, which was composed of over 100 associates, working in two 12-hour shifts.
  • Maintained excellent communication with customers and suppliers.
  • Constant long-term strategic planning of future growth and expanded facility capabilities.
  • Consistently maintained expenses below budget.
  • Created SOPs for all distribution and warehousing operations and tasks.
  • Reliability in preserving high quality standards in the largest and most complex Toro DC center.
  • Responsible for worldwide product delivery, product shipment quality and customer satisfaction.
  • Implemented 5 Why, 5S, Root Cause Analysis, Lean manufacturing to improve productivity.
  • Established payroll incentive and work recognition systems for employees.
  • Managed daily shipments over $1.9 million.
  • Responsible maintaining C-TPAT and BASC compliance.
  • Created a paperless WMS system to control inventory and picking and shipping process.
  • Responsible for all testing and implementation of new shipping control systems and programs.
  • In charge of supervising and shipping about 5 weekly international containers.
  • Coordinated the shipping of around 250 LTL per month.
  • Responsible for 320 truckload shipments per month, offload of about 400 finished goods trucks per month.
  • Responsibility for meeting all customer routing instructions in their shipments.
  • Over- sight of all plant quality levels and customer satisfaction metrics.
  • Decreased overall inventory dollar value from $63,787,605 in December of 2008 to $24,195,103
  • Improved overall shipping accuracy for customer deliveries to over 99.95 %
  • Increased productivity and lowered overall headcount by 40 %
  • Reduced customer shipping cycle by more than 50%, with 85% of current day customer orders shipping the same day. The other 15 % were normal 48-hour full truckload and over-sea containers.
  • Motivated and improved productivity by temporary employees into Toro employees.
  • Successfully replaced the need for a yearly 4 Wall Inventory and closing the facility down for 3 to 4 days affecting customer requirements, to a yearly one-day Statistical Inventory.
  • Effectively reduced shipping errors from a high of 155 per month with 55,000 shipping lines done daily to less than 25 per month with the same lines per month.
  • Increased inventory accuracy and bin reliability by establishing a full-time cycle count team.
  • Excellent consistent Statistical Inventories 99.98% financial accuracy and 99.96% material accuracy.
  • Successfully implemented WMS system, making entire operation paperless.

General Manager of Mexican Operations

Modern Metal Products Mexico
Cd. Juarez, Mexico
12.1998 - 01.2007
  • Managed border crossing planning between the Mexican manufacturing plant, the El Paso, Texas warehouse and the distribution center.
  • It was a three-shift operation with 450 direct associates, 50 indirect and 9 department managers.
  • I established the operation from green field start-up to full manufacturing capacity.
  • I had responsibility for all strategic planning, and full P&L results for this Mexican manufacturing operation.
  • Maintained all associates focused on Continuous Improvement efforts.
  • Maintain strong policies to promote low turnover and absenteeism.
  • Implemented Lean manufacturing techniques to improve productivity and manufacturing costs.
  • Coordinated Mexican customs, logistics traffic, and HS tariff code assignments.
  • Established payroll incentive and work recognition systems for employees.
  • Write and develop all SOPs for all operations and support tasks.
  • Established strong Quality systems and line inspection processes.
  • Maintained complete control over all headcount growth in both the manufacturing plants.
  • Established MRPII system with strict BOM, inventory controls, scheduling, and distribution procedures.
  • Coordinated customs department to meet MRP requirements by setting up JIT border crossing schedules to not only meet raw material requirements, but also to maintain low inventory.
  • Responsible for all ISO/TS 16949 procedure audits and compliances.
  • Controlled plant quality levels and customer satisfaction.
  • Established Kanban systems for raw material replenishment of the production cells which span two countries and compensates for US and Mexican border crossing times.
  • The Mexican operation took less than 6 months to go from an empty building to a full manufacturing operation.
  • Created a strong manufacturing focus and associate accountability on customer service.
  • The operation began with a single product line supplying a single automotive assembly plant, to over 100 product lines supplying over 35 assembly plants.
  • Set up Lean Manufacturing practices.
  • Established strict problem-solving procedures and a CAPA program to promote Root Cause analysis.
  • Roles and Responsibility list was made for all team associates so everyone could be accountable.
  • Established a disciplined 5S, Visual Factory, JIT and Kanban systems in the plant.
  • Established local and regional raw material suppliers’ networks for a low-cost sourcing strategy.
  • Doubled the size of the manufacturing plant in square footage, headcount, and customer programs.
  • Assisted in establishing a secure system of poke yoke and sensors throughout the manufacturing areas to assure quality standards and strict guidance to processes.

Plant Operations Manager

HFI Mexico
Cd. Obregon, Mexico
02.1987 - 12.1998
  • Responsible for total facility P&L results.
  • A three-shift manufacturing operation with a labor force of 560 direct, 45 indirect, and 9 department managers.
  • Created all SOPs for all manufacturing operations and support tasks.
  • Supervised and ensured all ISO/TS 16949 procedures are maintained.
  • Established Lean Manufacturing techniques.
  • Maintain strong policies to promote low turnover and absenteeism.
  • Corrective Action and Root Cause Analysis procedures were established.
  • Establish strong Quality systems and production inspections.
  • Responsible for strategic planning of new business projects, and capital expenditures.
  • Coordination of the entire Mexican automotive manufacturing/supply chain operations.
  • Assured that all customer releases were shipped on a timely basis.
  • Control headcount growth in our Mexican operations.
  • Supervised inventory levels in raw materials and finished goods.
  • Established incentive plans for operator motivation and recognition.
  • Responsible for programs to reduce production scrap and increase plant efficiency.
  • Established strict and disciplined MRPII / Supply Chain procedures.
  • I had regular audits of all BOM’s to assure actual usage was accurate.
  • Keep good relations with the plant workers union and negotiate the union contract.
  • Managed a purchasing team of 3 associates, constantly looking for cost reduction opportunities.
  • Contributed to the development of Mexican suppliers to meet efforts in reducing over-all manufacturing costs in Mexico.
  • Successfully took this Mexican manufacturing facility from 100 associates to over 600 associates.
  • Built a strong manufacturing mantra of Quality and a focus on customer satisfaction.
  • Established a strategic partnership with a 3PL operation in Nogales Arizona to manage all our north-bound finished goods, and south-bound raw materials and purchased parts.
  • Trained all associates in Lean manufacturing ideas, 5S concepts, and 5 Why and Root Cause problem solving analysis.
  • Created team building programs and ideas to foster associate pride and loyalty in their work and in their company.
  • Created cross-functional teams to constantly look for Continuous Improvement ideas.
  • Established a full-time cycle count team to maintain control of our inventory accuracy.
  • Consistently passed all TS 16949 compliance audits.
  • Established fully integrated “U” cell production units to maximize Lean efficiency and floor space.
  • Created clear Roles and Responsibilities for all production and management team associates in order to hold people accountable.

Education

Master of Arts Degree - Economics

University of Texas at Austin
Austin, TX

Bachelor of Arts Degree - Political Science/Economics

Texas A&M University
College Station, TX

Skills

  • Lean Manufacturing
  • Quality Management
  • Cost Reduction
  • Kanban / JIT
  • GMP
  • MRP / Scheduling
  • Inventory Management
  • Import/Export Process
  • Cross Border Operations
  • Best Practices
  • S&OP Leadership
  • PFEP
  • Gemba Walks
  • Budget / P&L Experience
  • Strategic Planning
  • Nutritional / Food Industry
  • Continuous Improvement
  • Packaging Redesign
  • CAPA (Corrective and Preventive Action)
  • ISO/TS 16949
  • Value Stream Mapping
  • WMS
  • Warehouse Management
  • Toyota Kata (Root Cause Analysis)
  • Procedure SOP Development
  • Materials Procurement
  • Logistics / Transportation
  • High Volume Manufacturing
  • Demand Forecasting
  • Kaizen event planning
  • 5 Why Root Cause Analysis
  • 8D Problem Solving Analysis
  • AS400
  • Windows
  • MRP II
  • MFG PRO
  • QAD
  • GSS
  • SAP
  • Plex
  • Dynamics AX
  • NetSuite
  • Google Docs
  • Continuous Improvement Plans

Timeline

Supply Chain Manager

National Wire
04.2025 - 08.2025

Production Control Manager

Reyes Automotive
02.2024 - 03.2025

Materials Management Consultant

AST Space Mobile
05.2023 - 12.2023

Distribution and Logistics Manager

The Jamco Group
08.2020 - 05.2023

Production Control and Logistics Manager

Android Industries, LLC
01.2014 - 08.2020

Distribution Center Manager

The Toro Company
01.2007 - 01.2014

General Manager of Mexican Operations

Modern Metal Products Mexico
12.1998 - 01.2007

Plant Operations Manager

HFI Mexico
02.1987 - 12.1998

Master of Arts Degree - Economics

University of Texas at Austin

Bachelor of Arts Degree - Political Science/Economics

Texas A&M University

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Alex Chaib