Summary
Overview
Work History
Education
Skills
Birthday
Civil Status
Cell
Academic Studies
Computing Skills
Birth Place
Personal Information
References
Training
Languages
Timeline
Generic
Carlos Julian Del Castillo

Carlos Julian Del Castillo

Winston-Salem,United States

Summary

Encouraging Leader and analytical problem-solver with talents for team building, leading and motivating, as well as excellent customer relations aptitude and relationship-building skills. Proficient in using independent decision-making skills and sound judgment to positively impact company success. Dedicated to applying training, monitoring and morale-building abilities to enhance employee engagement and boost performance.

Overview

26
26
years of professional experience

Work History

Plant Director - U.S.

VITRO AUTOMOTIVE
05.2022 - Current
  • Turnaround Plant Operation by building a Culture of Operational Disciplines and transfer financial knowledge through the organization for better decisions to get good results
  • Exit Customer escalation process during 90 days by having transparency on the Quality and Production (Deliveries) plan
  • Prepare and involve Leadership Team to build 2023 budget, based on Volume, Sales, Performance and resources required to accomplish budgeted targets.
  • Established metrics-driven performance management systems that encouraged accountability and fostered a high-performance work environment.
  • Led continuous improvement initiatives that resulted in significant waste reduction and improved process capabilities at the facility.
  • Developed strategic plans to optimize resources, drive cost savings, and achieve operational excellence in the facility.

Director of Operations - Latin America

VITRO AUTOMOTIVE
05.2021 - 05.2022
  • Responsible to keep Operational Stability for 4 Plants with more than 3.800 people, by using Key Performance Indicators (People, Delivery, Quality, Efficiency & Cost)
  • Strong follow up on Financial performance and Operational Disciplines to turn around into a positive result through a strategy and plan to recover and stabilize the operations
  • Indirect Staff Report: PC&L, Finance, HR and Engineering
  • Key activities to generate Cash Flow is to Control Raw & Finish Good Material inventories to avoid Obsolescence, Scrap, Increase Efficiency and Manufacturing Cost Control.
  • Developed systems and procedures to improve operational quality and team efficiency.
  • Monitored budget and utilized operational resources.
  • Conducted regular performance reviews to assess team progress, providing constructive feedback and guidance for continuous improvement.
  • Collaborated with senior management to develop and execute long-term corporate goals and objectives.
  • Managed budgets and resources, optimizing allocation for maximum impact on business objectives.

Director of Manufacturing Operations - Northeast

APTIV
07.2019 - 04.2021
  • Responsible to keep Operational Stability for 6 Plants with more than 14,000 people, by using Key Performance Indicators (People, Delivery, Quality, Efficiency & Cost)
  • Strong follow up on Financial performance and Operations Disciplines to turn around into a positive result through a strategy and plan to recover and stabilize the operations
  • Indirect Staff Report: PC&L, Finance, HR and Engineering
  • Key activities to generate Cash Flow is to Control Raw & Finish Good Material inventories to avoid Obsolescence.
  • Set product standards, examining samples of raw products and processing tests, to monitor quality of finished products.
  • Reviewed processing schedules and production orders concerning inventory requirements, staffing requirements, work procedures and duty assignments, considering budgetary limitations and time constraints.
  • Increased production efficiency by implementing lean manufacturing principles and streamlining processes.
  • Evaluated employee skills and knowledge regularly, training, and mentoring individuals with lagging skills.

Director of Manufacturing Operations

YAZAKI NORTH & CENTRAL AMERICA
04.2016 - 07.2019
  • Indirect responsibility through Strategic Development to keep Operational Stability of 52 Plants by using Key Performance Indicators (People, Delivery, Quality and Cost) to allow me to make decisions based on financial performance (P&L) without compromising People Safety and Quality and Deliver to customers
  • In charge of the SAP Team to implement to each one of the plants by using a Master schedule and risk assessment tools to prevent and predict for any roadblock identified
  • With the help of this SAP Team I was able to Control Warehouse and Shop Floor Inventory with a reduction that went from a loss of $3,000 KUSD to $500 KUSD within 4 months
  • Also responsible for the Transfer team to create capacity for future programs or rightsizing plants according to customer requirements.
  • Reviewed processing schedules and production orders concerning inventory requirements, staffing requirements, work procedures and duty assignments, considering budgetary limitations and time constraints.
  • Led improvement initiatives to advance operational efficiencies and increase revenue.

Senior Manufacturing Support

YAZAKI NORTH & CENTRAL AMERICA
09.2014 - 04.2016
  • Implement Standard Visual Management, KPI´s and Best Practices for the 52 facilities all over México, El Salvador and Nicaragua
  • Support Manufacturing Operations during Crisis mode to avoid any customer disruption in regards to Delivery, Quality and Cost
  • Manufacturing Cost Management & Control to achieve Budget according to Plan.
  • Managed multiple projects simultaneously under tight deadlines without compromising quality or customer satisfaction levels.
  • Reduced equipment downtime by conducting regular maintenance checks and addressing issues promptly.
  • Led team efforts in achieving production goals while consistently meeting quality requirements and customer specifications.

Plant Manager

FAURECIA EXTERIORS ARGENTINA - Launch of New Plant Division
02.2012 - 08.2014
  • Launch of New Plant Division for Injection, Painting and Assembly of Front Bumpers for VW Amarok Project as a Just In Time Plant
  • Selection of the Management Team: H.R., Logistics, Maintenance, Engineering, Quality, Production and Plant Controlling
  • Coordinate Building Construction, Installation and start up activities of New Equipment: Robot Installation at Injection and Painting Line, obeying the main process flow and production level.
  • Increased production efficiency by optimizing plant layout and implementing process improvements.
  • Reduced costs by eliminating materials waste and unnecessary labor hours.

Production Manager from Interior Injection

FAURECIA ARGENTINA (Faurecia Interior Systems)
09.2011 - 02.2012
  • Accomplish production plan for every one of the injection machines (Krauss Maffei 2000, 2300 and 2600 tons) according to the tool changes (SMED) with reference on interior moldings such as: Door Panels, Consoles, Instrument Panels and other small injection moldings for the different customer brands: Ford, GM, Renault and Peugeot.
  • Resolved issues quickly to maintain productivity goals.
  • Managed multiple projects concurrently, ensuring timely completion and meeting budget constraints.
  • Increased overall productivity by identifying bottlenecks in the production process and proposing effective solutions.

Door and Trim Assistant Manager

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
07.2003 - 07.2011
  • Coordinate and Develop Systems & procedures for Takt Time Changes, Leadership Development and Behavior (Line Supervisors) for Floor Management to sustain and improve the shop.
  • Supervised day-to-day operations to meet performance, quality and service expectations.
  • Maintained a clean, safe, and organized store environment to enhance the customer experience.
  • Developed strong working relationships with staff, fostering a positive work environment.

Final Area Group Leader - Production Engineer

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
08.2008 - 12.2009
  • Coordinated 22 Associates to work within a Safe place, to build Quality in the Process with a high Efficiency and low Cost
  • Enhance people mindset to educate them through the Toyota Way and TPS fundamentals by using the Floor Management System to communicate and improve results on a daily basis
  • Also, Project Leader for volume reduction (Takt Time Change Decrease) project to reduce impact on dealer inventory, improve process efficiency and build units as customer demands.
  • Led by example, demonstrating commitment to the company''s mission and consistently delivering high-quality work.
  • Developed a collaborative work environment through open communication and regular team meetings, enhancing overall group performance.

Door and Trim Product Specialist and Project Leader

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
07.2003 - 07.2008
  • Experience on Launch New Mexico Plant and launch new models, equipment buy-off (Kanban), process design, strong knowledge on TPS and Toyota Way, problem solving experience, operating plans developments, develop and control budget expenses and team coordination for new projects
  • Process design and Set-Up for trim area: door panel, electrical components & wire harnesses, Instrument Panel Assembly, Windshield Assembly.
  • Collaborated with cross-functional teams to streamline product development processes.
  • Effectively resolved any potential issues or roadblocks during the development process by maintaining clear communication channels among all relevant departments.

Manufacturing Leader at Trim Area

FORD HERMOSILLO STAMPING AND ASSEMBLY PLANT
12.1998 - 01.2003
  • Experience on Launch models, Standardized processes, layout operation (visual factory) and sequence operation
  • FPS (Ford Production System), Lean Manufcturing and 6sigma (Green Belt) tools were used to improve processes and continue improvements.
  • Analyzed production data to identify trends and opportunities for improvement in overall plant performance metrics.
  • Collaborated closely with cross-functional teams to identify areas of improvement and implement process enhancements for increased productivity.
  • Improved product quality with meticulous attention to detail and adherence to strict quality control standards.
  • Reduced downtime by conducting regular equipment maintenance checks and addressing potential issues proactively.

Liaison Quality Engineer

ALTEC ELECTRONICS FROM CHIHUAHUA
07.1998 - 12.1998
  • Quality Product Assurance to the customer directly, track critical issues before and after it arrives to the customer, Link between Altec Chihuahua and Customer (Ford Motor Company)
  • Participate on electrical VRT lead by Ford people where the main goal was to reduce variability of the process due to electrical components failures at customer (Warranty): Stereo ICP, cruise control, amplifier and cluster.
  • Served as the primary point of contact, fostering strong relationships between internal teams and external partners.
  • Coordinated multiple projects simultaneously, ensuring timely completion and alignment with organizational objectives.
  • Maintained a high degree of professionalism at all times, representing the organization with integrity in both internal and external interactions.

Quality Supervisor

LEONI CABLE
04.1998 - 07.1998
  • Ensure Quality of electrical Wire harness by dimensional and functional test
  • Sustain and improve quality performance to real-time feedback on electrical quality issues within the process: Set-up of crimping machine, wire path board, electrical test, terminal connection, electrical drawing reading
  • Participating in problem-solving activities of customer claim due to electrical issues.
  • Reduced customer complaints by addressing root causes of quality issues and driving continuous improvement initiatives.
  • Enhanced product quality by implementing stringent inspection processes and providing comprehensive feedback to production teams.

Education

Bachelor of Science - Industrial Engineering

Universidad Del Valle De Mexico
12.1998

Skills

  • Training and mentoring

  • 5S methodology

  • Safety Management

  • Customer Focus

  • Operations Management

  • Staff Development

  • Waste Reduction

  • Production Scheduling

  • Cost Reduction

  • Total Productive Maintenance

  • Team building and development

  • Plant and warehouse operations

  • Schedule Management

  • Continuous Improvement

  • Project Management

  • Cost controls

  • Production Planning

  • Performance Improvements

  • Project Coordination

  • Lean manufacturing principles

  • Cost Control

  • Lean Manufacturing Processes

  • Six Sigma expertise

  • Environmental Sustainability

  • Teamwork and Collaboration

  • Customer Service

  • Team Leadership

  • Decision-Making

  • Effective leader

  • Relationship Building

Birthday

03/26/75

Civil Status

Married

Cell

+1 (336)-909-3186

Academic Studies

B.S. Ind. Eng., Universidad del Valle de México, Hermosillo, Sonora, Mex, 1994-1998

Computing Skills

  • Windows
  • Excel
  • Word
  • Powerpoint
  • AutoCAD

Birth Place

Hermosillo, Sonora, Mex

Personal Information

Title: Industrial Engineer

References

  • Juan Luis Burgueño, (+52 1 664) 354-6553, Tecate, Baja California Norte
  • Jesús Bañuelos, (+52 1 656) 359 - 2134, Monterrey, Nuevo León, México
  • Luis Angulo, (+52 1) 81-8658-0660, Monterrey, Nuevo León, México

Training

  • FPS Boot Camp (Ford Process System)
  • Lean Manufacturing
  • 6-Sigma Green Belt (Certified)
  • FMEA (Failure Mode and Effect Analysis)
  • Diversity and Ethics
  • TPS (Toyota Production System)
  • 7Quality Basics
  • Employee Empowerment
  • Just In Time
  • TPM
  • Plant Management Control
  • Problem Solving
  • Safety Risk Assessment
  • P&L
  • Negotiation Training
  • Communication and Basic Finance Training at France
  • Injection and Painting for exterior plastic parts training at France and Brazil

Languages

English
Full Professional
Spanish
Native or Bilingual

Timeline

Plant Director - U.S.

VITRO AUTOMOTIVE
05.2022 - Current

Director of Operations - Latin America

VITRO AUTOMOTIVE
05.2021 - 05.2022

Director of Manufacturing Operations - Northeast

APTIV
07.2019 - 04.2021

Director of Manufacturing Operations

YAZAKI NORTH & CENTRAL AMERICA
04.2016 - 07.2019

Senior Manufacturing Support

YAZAKI NORTH & CENTRAL AMERICA
09.2014 - 04.2016

Plant Manager

FAURECIA EXTERIORS ARGENTINA - Launch of New Plant Division
02.2012 - 08.2014

Production Manager from Interior Injection

FAURECIA ARGENTINA (Faurecia Interior Systems)
09.2011 - 02.2012

Final Area Group Leader - Production Engineer

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
08.2008 - 12.2009

Door and Trim Product Specialist and Project Leader

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
07.2003 - 07.2008

Door and Trim Assistant Manager

TOYOTA MOTOR MANUFACTURING DE BAJA CALIFORNIA
07.2003 - 07.2011

Manufacturing Leader at Trim Area

FORD HERMOSILLO STAMPING AND ASSEMBLY PLANT
12.1998 - 01.2003

Liaison Quality Engineer

ALTEC ELECTRONICS FROM CHIHUAHUA
07.1998 - 12.1998

Quality Supervisor

LEONI CABLE
04.1998 - 07.1998

Bachelor of Science - Industrial Engineering

Universidad Del Valle De Mexico

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Carlos Julian Del Castillo