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Eliud Castillo Saavedra
Plant Quality Manager
South Grafton,USA
Summary
Quality management professional with proven success in enhancing operational excellence within tier 1 automotive environments. Achievements include leading cross-functional initiatives that lowered costs associated with poor quality and elevated customer satisfaction levels. Expertise in conducting audits and compliance activities to ensure ISO and IATF standards are met across various regions.
Overview
1
1
Certification
24
24
years of professional experience
Work History
Manager Corporate Quality & Plant Quality Manager
Aspen Aerogel
East Providence, Rhode Island
01.2024 - Current
- Led enterprise-wide quality management system (QMS) with ISO-9001 and IATF-16949 across manufacturing suppliers and product development.
- Directed cross-functional quality initiatives to standardize processes across operations, engineering, supply chain, and R&D.
- Managed supplier quality lifecycle, including validation, LPA audits, APQP-PPAP phases 1-4, and process inspections, ensuring alignment with quality standards.
- Implemented root cause and corrective action processes using 8D, 5 Whys, cause mapping, and DMAIC to reduce defects.
- Conducted internal and external audits, ensuring compliance with customer and regulatory inspections.
- Drove continuous improvement programs using SPC process capability (Cp-Cpk) to systematically address and reduce Cost of Poor Quality (CoPQ).
- Developed quality KPIs that provided actionable performance insights and supported strategic improvement plans for executive leadership meetings.
- Transitioned ERP project from Oracle to D365 by integrating quality system with customer-specific requirements.
Director of Quality
Rev Group ENC El Dorado National Group
Riverside, California
05.2023 - 12.2023
- Led internal and external ISO-9001 audits to verify adherence to standards and procedures.
- Ensured ISO-9001 certification compliance by managing quality management system effectively.
- Managed four quality managers to elevate customer service and strengthen supplier quality assurance.
- Implemented global quality standards across production, ensuring compliance with FMVSS regulations.
- Expanded quality laboratory capabilities, increasing accuracy of warranty claims and inspections.
- Trained multidisciplinary teams on problem-solving techniques, addressing customer concerns via 8D reports.
- Improved component data accuracy through enhanced inspection processes and systematic improvements.
Director of Quality
Horizon Global
McAllen, Texas
01.2020 - 05.2023
- Implemented Global Quality Standards in all productive areas through training and accountability for multifunctional teams at Horizon Global facilities, including plants in Romania, France, and Germany.
- Led internal and external IATF 16949 quality audits to assess compliance with customer and corporate standards.
- Managed five plant quality managers across metals process and electrical manufacturing plants at two distribution centers in Edgerton, Kansas, and McAllen, Texas.
- Executed ranking and improvement action plans for steel suppliers, preventing potential customer impacts.
- Reviewed 8D reports within 24 hours for immediate containment actions; implemented root cause analysis within 15 days, closing corrective actions within 30 days to expedite resolutions.
- Instituted Layer Process Audits for customer complaints, engaging staff management teams in problem resolution.
- Integrated supplier quality manual into contracts, ensuring compliance prior to issuing purchase orders.
- Oversaw problem resolution system at Enterproj, presenting findings at board meetings and coordinating reviews across plants.
Plant Quality Manager
Magna International
San Luis Potosi, S.L.P.
01.2016 - 12.2019
- Manage 4 Senior Quality Leaders, 8 QA Engineers, 15 Quality Control and 45 quality inspectors to support hot stamping, stamping, laser and assembly department.
- Reduction by 30% in customer complaints and improvements (Permanent Corrective Actions) audited by the customers: GM and Ramos plant, VW, Honda and Nissan.
- Responsible for KPI, FTQ (First Time Quality) reduction of 35% internal complaints.
- Implemented zero defect and self-inspection culture in all productive areas by training direct labor in product specification.
- Continuous improvement process based on RPN reduction from PFMEA, Pass Thru and Critical Characteristics.
- Implemented layer process audits for customer complaints and repetitive issues, engaging staff management team in the quality system.
- Oversaw CAR (corrective action reports) system and evaluated evidence presented in board meetings to ensure accountability and compliance.
- Reviewed the 8D reports within 24 hours for immediate response and containment into Covisint system, implemented root cause within 15 days, and closed corrective actions within 30 days.
- Supplier Quality Development: Implementation of Global Quality Standards (GQS) & Mafact for process controls system.
- Critical steel suppliers ranking and improvement action plan to avoid customer impacts.
- Continues improvement process based on RPN reduction from PFMEA, Pass Thru and Critical Characteristics.
- Analyzed reports to justify financial standings related to scrap, cost of quality, and implemented cost savings improvement projects.
- Implement new technology such as vision system in stamping and assembly to improve the product inspection.
- Training to all the quality inspectors, engineers and technicians in GD&T in order to review print spec and inspection methods (First Article Inspection).
- Lead the dimensional wall at the CMM metrology laboratory and integrate tooling core team and welding CWE and cut & etch leader.
Quality Superintendent
Magnapowertrain
Monterrey, Nuevo Leon
11.2006 - 12.2015
- Manage 2 Senior Quality Engineers, 4 Quality Assurance Engineers and 30 quality inspectors to support CNC Machining and assembly department.
- Led cost savings project for vacuum pump system in Germany, achieving targeted 3-piece price discount through competitive analysis.
- Prepared monthly executive reports for top management, detailing KPIs and project status related to quality, cost, and timing.
- Delivered executive presentation on GPMS gate reviews to inform management about project progress.
- Facilitated detailed project discussions with customers during launch phase to address quality concerns.
- GPMS and APQP Implemented for Safe Launch in: GM (GP12), Chrysler (FSCP), Ford, VW Audi and Mazda.
- Committed with the team to award Ford Q1 Score 1000 points the maximum qualification, 1600 for 3 months and not least than 1300 points.
- Implemented Safe Launch for all new projects: VW Audi Vacuum Pump with non-major complaints and 3.4 PPMs.
- Leading the core team in all preventive core tools: PFMEA and RPN reduction program, Process Control Plan and Improvement, Error proofing and detection systems in production lines, operator training in PTC and Interface Characteristics.
- Improved GQS audit scores across all elements from 0.8 to 4.2, targeting excellence in Magna's North America.
- Enhanced Root Cause Analysis System by implementing 8D and 7-step methodologies along with additional problem-solving tools.
- ISO-TS Re-certification with 0 major issues and 3 minor issues; observations were closed during audit process.
- Managed implementation of continuous improvement teams in production lines using Gemba Kaizen methodology.
- Conducted GQS and layer process audits at GM, DCX, GM STT, and Ford assembly line for new projects.
- Managed product inspections for shipments to GM St. Catharines and Romulus engine plant, collaborating with third party sort company in Ontario.
Process Quality Engineer
HALDEX
Monterrey, N.L.
12.2001 - 10.2006
- Supervisor for 10 QA inspectors to release finished goods in production lines, subassemblies and work in process.
- Monitored KPI indicators including FTQ, internal/external PPM, and scrap rates by production line, utilizing pareto charts to identify and address improvement actions.
- Implementation of SPC in plant, introducing control charts X-R, calculation of CPK, graphic P for attributes.
- Implemented PCP, PFMEA (support), APQP, and monitored PPAP, gage R&R, and MSA of new products and materials.
- Zero Defects Program at production by implementing poka yokes at assembly lines for the critical characteristics.
- Led continuous improvement teams to implement in production lines by using Gemba Kaizen methodology.
- Managed machining, assembly, stamping, MIG welding, warranty processing, and testing processes for brake systems to ensure optimal functionality and quality.
Education
MBA - Business Administration And Management
EGADE Business School (ITESM: Tecnologico De Monterrey)
Monterrey, N.L. Mx12-2013
MBA - Management Information Systems
UANL EGAI
Monterrey, Mexico12-2010
Six Sigma Qualified-Certified Black Belt -
UANL
Monterrey N.L. Mx12-2004
Bachelor of Science - Industrial Engineering
UANL
Monterrey N.L. Mx01-2002
Skills
- Quality management and auditing
- ISO compliance
- Supplier quality assurance
- Regulatory compliance oversight
- Process improvement strategies
- Quality assurance strategies
- Root cause analysis
- Project management and planning
- Data analysis and reporting
- Operations management efficiency
- Key performance indicators (KPIs)
- Risk management practices
- Performance management systems
- Customer focus and service
- Customer relationship management (CRM)
- Strategic planning initiatives
- Budget control measures
- Shift scheduling coordination
- Innovation management strategies
- Team leadership and collaboration
- Cross-functional teamwork dynamics
- Effective communication skills
- Coaching techniques
- Time management proficiency
- Decision-making processes
- Problem solving techniques
- Complex problem solving
- Goal setting
- Critical thinking abilities
- Coaching techniques
Training
- Six Sigma Champion training Certified Black Belt (UANL)
- Qualified in 8D’s, Minitab, SPC, GD&T (Geometric and Dimensional Tolerancing) 14.5-2009 and MATEC.
- GPMS (Global Program Management System) by Magnapowertrain & Magna SLMF.
- APQP & PPAP training by TAC company.
- Lead auditor & Internal auditor in: IATF 16949 by Intertek, ISO 9001, ISO 14001 and ISO13485.
- Q1 Process with Ford FoMoCo.
- Warranty Training (AWS – Ford, PRAS / WIS – DCX).
- Formal Q VW, QPN (Phases APQP) VW-Audi EA888.
- BIQ (Build in Quality) & QSB (Quality System Basics) by GM.
- PSO 5.6 Daimler Chrysler-FCA-Stellantis.
- SWOT analysis for Strategic Product and Manufacturing Process.
- Cash Management / Annual Department Budget-forecast and monthly spent.
Languages
- English
- Spanish, Native
- English, Professional working level
Certifications And Education
- MBA, EGADE Business School (ITESM: Tecnologico de Monterrey), 08/01/11 - 05/01/13
- Masters in General Administration and Industrial Engineer, UANL EGAI, 08/01/09 - 05/01/11
- Six Sigma Qualified-Certified Black Belt, 08/01/04 - 12/01/04
- Industrial Engineer, UANL, 08/01/98 - 05/01/02
Languages
Spanish
Native/ Bilingual
English
Full Professional
Certification
- IATF 16949 Internal Auditor
Timeline
Manager Corporate Quality & Plant Quality Manager
Aspen Aerogel
01.2024 - Current
Director of Quality
Rev Group ENC El Dorado National Group
05.2023 - 12.2023
Director of Quality
Horizon Global
01.2020 - 05.2023
Plant Quality Manager
Magna International
01.2016 - 12.2019
Quality Superintendent
Magnapowertrain
11.2006 - 12.2015
Process Quality Engineer
HALDEX
12.2001 - 10.2006
MBA - Business Administration And Management
EGADE Business School (ITESM: Tecnologico De Monterrey)
MBA - Management Information Systems
UANL EGAI
Six Sigma Qualified-Certified Black Belt -
UANL
Bachelor of Science - Industrial Engineering
UANL