Alex Rosas

I have been an Integer as an Operations Manager for a little over 90 days now, and it has been a journey. Getting to understand our processes, learn the way production works as well as other departments. My biggest take away so far is that in this company, more than any others I've worked before, the key is our success is collaboration. The success of each department depends so much in the others that collaborating and strategizing together is the only way.

• In collaboration with EHHS, ensured compliance with safety regulations and maintained a safe work environment for all personnel.
• I have learn, monitored and improved efficiency of processes.
• I am the champion on 3 different projects, strategizing and challenging the team to move in the right direction in a timely manner.
• Directed operations staff by providing coaching and support in order to meet company objectives.
• I have Identified leadership skills opportunities and gaps within the leadership team and I provide daily coaching
• Analyzed data from daily reports to identify trends in production performance metrics.
• Coordinated with other departments including engineers, quality, continuous improvement, human resources to ensure efficient operations.
• Developed key performance indicators to measure effectiveness of operational processes.
• Performed cost analysis for various projects to determine budget requirements.
• Gathered, analyzed, and interpreted data from multiple sources for the purpose of preparing accurate reports.
• Assisted in developing dashboards and visualizations to enhance the presentation of reports.

At TBG I have had the opportunity to highly impact the company with sustainable changes and results. I fit in perfectly with the company’s values and I live by them. I directly work with managers, supervisors, and leads daily to coach them on leadership, safe, and quality driven manufacturing practices, and continuous improvement.

I am directly responsible for 6 different departments of this organization; CNC Machine Room, Acrylics Fabrication, Fixtures Assembly, Fulfillment Fixtures Assembly, Prototyping, and Scheduling.

Here are some of my day to day responsibilities:

• Motivate, mentor, coach, manage, and train employees for professional development, employee engagement, and the creation of a safe and inclusive environment.
• Maintain thorough understanding of all assigned projects and/or accounts, their timelines, scopes, and resourcing needs.
• Evaluate production requirements of assigned projects, including business requirements and material or technical specifications.
• Plan production strategies and time tables; Prioritize, analyze, and implement more efficient, and effective work flows with the goal of optimizing the work output of the team with quality as a focus.
• Act as a liaison with other internal departments within TBG to ensure clients’ needs are being met in accordance within project scope, budget, and timelines. Ensure assembly integrity through continuous monitoring of departmental processes
• Anticipate production needs and problems and bring up concerns immediately to direct supervisor so any remediation necessary can be quickly implemented.
• Established open lines of communication within the production floor to circulate production details and produced elements for internal review while maintaining production timelines.
• Maintain expertise with new technology, trends, prices, production techniques, and suppliers.
• Support a safe environment, driving towards 0 OSHA recordables.
• Represent corporate policy and communicate to employees as required
• Work to further develop skills and knowledge of team members
• Drive improvements in material flow, including cell design and material delivery. Interact with other support departments as necessary.

Accomplishments:

-Employee Engagement:

TBG partners with an analytic advisor company named Gallup to conduct yearly company wide survey's to measure employee engagement as a third party. The survey measures and filters through different teams to score leaders on their teams engagement on a range of 1-5.

Historically, the first year my team scored a 4.21, followed by a 4.74, and recently a 4.83; The most recent result I am proud to say was the highest score in the company.

-Safety:

Coached, and mentored safety site leads, and employees to support our safety procedures. As a result there have been 0 recordable incidents in the last 3 years.

-Quality:

During my first year, I helped develop the first training programs by putting structure towards developmental tiers, SOPs, and standards throughout all of the Internal Fixtures departments, which later became the structure for other teams within the company. We have four different quality measurables for each job ran that is called, "The FAB4". In addition, I continuously work with other teams of the organization to better serve and support each other.

-Efficiencies:

In collaboration with the Director of Continuous Improvement, we developed CI Classes and GEMBA walks, to allow employees and teams to better understand their impact on a day to day basis. Through nurturing and teaching good manufacturing practices, I was able to raise the average on-time delivery percentage from 63% to 96% with only a .54% being reworked on all jobs. In addition, we developed a daily production meeting to better understand and forecast the needs from our ever growing and changing organization.

Daily collaboration with Engineering and R&D departments to streamline and create new processes to further support manufacturing best practices.

Also, I received an award for a Brown Belt Achievement Title because I was able to save $137,000 on temp labor to the company within my 2nd year.

This has been one of the most rewarding experiences. BE Pressure is a global corporation invested in power equipment and AG parts. At BE I've had the opportunity to help transform an already successful business, into a world class company.

Production:

• Coach and develop team leads on best manufacturing practices, safety and efficiency
• Implementation of 5S and LEAN procedures.
• Analyzed the current state and develop value stream charts in order to make the flow more efficient.
• Planning, strategy decisions, and setting SMART goals.
• Make production processes safe, excellent, and cost effective.
• Quality measurables at receiving, and production stations to document and resolve supplier corrective action reports (SCAR).
• Responsible for cost, compliance, product quality, efficiency, product turn-around time and employee engagement.
• Develop continuous improvement culture and processes to meet our dead lines.

Quality:

• Planning, strategy decisions, and setting SMART goals.
• Develop a matrix to approve the right products or reject defective ones.
• Make sure that all supervisors perform quality inspections in their designated areas.
• Created check points to ensure that our orders were picked accurately. Items, quantities etc

Safety:

• Participated as safety capitan on the safety committee, train personnel and promote a safe culture.
• Learn, develop, and apply written safety procedures.
• Observe work areas during weekly safety walks.
• Investigative incidents and accidents to prevent repeat incidents.
• Develop a near miss report and inspire employees to report them.

Leadership:

• Responsible for the overall strategic direction, coordination, and success of each department. Provide effective, safe, and efficient working conditions, space, resources, and a positive environment that will maximize the effectiveness of employees in accomplishing the objectives of the company.
• Develop & mentor employees. Direct & assign work, administer labor contract and compliance. Foster positive workplace. Communicate effectively
• Directed the strategic team to design, develop and carry out business operating models – including vision, strategy, performance metrics.
• Recruiting and building a team with strong values.
• Develop and implement 1-1 meeting between supervisors and team members.

One of the most important responsibilities I had was forecasting; It was imperative to be able to predict what will happen for weeks in advance. On an average day I supervised and coached personnel and managed the daily production in all areas. I assured that all jobs in progress go without any issues and prevent future issues from arising. I made sure the department meets the deadlines while producing a high quality product.

Quality:

Quality control was a very important part of this role. At MKM we produce items that were for hospitals; such as a blood filter; Performing daily quality inspections was a must.

• Reading blueprints and instructions to comprehend the quality expectations for the product and supplies.
• Approving or rejecting raw materials with respect to quality standards, and record supplier performance, per batch.
• Entered information into system to update status reports.
• Developed effective scheduling processes to achieve production objectives.
• Selecting output samples and quality checking them using appropriate methods.
• Keep accurate documentation and perform analysis report.
• Make sure that all supervisors performs quality inspections in their designated areas.

Accomplishments

One of my biggest accomplishments at Minnesota Knitting Mills was to meeting our customer's needs. When I started working at MKM, the company was able to produce 34,000 pieces a month of this specific item and the goal was to produce 100,000 pieces per month.

After doing a deep analysis of our processes and implementing some strategic changes, 3 months after I started we shipped 75,000 pieces, a month later 103,000 pieces and right on track for 105,000 pieces after that.

This was an incredible team achievement of course, but a big part of this success was my ability to see our current process and improve it, by doing several time studies, work flow improvement, quality control, scheduling accuracy, and process development. By putting people in the right places, giving them strategic coaching, and achievable S.M.A.R.T goals we were able to make this happen.