Estevam Lima
Alpharetta,GA
Summary
25+ years of experience in large companies acting in different processes. Experience in Production, Continuous Improvement, Processes and Quality Management. Development, implementation and audit of policies and standards, with knowledge of international standards ISO 45001, ISO 14001, ISO 9001, GMP, API Q1, Q2 and 17J. Project Management (PMP). Results management by KPI. Solid knowledge in Agile, TPM, Lean and Six Sigma (Green Belt) methodologies. Strengths: teamwork, leadership, creativity and focus on results.
Overview
33
33
years of professional experience
Work History
Manufacturing Director
Nutracap Labs (Dietary Supplements and Cosmetics Manufacturer)
04.2022 - Current
- Responsible for operation of two plants (Dietary Supplements and Cosmetics), one warehouse (raw material and packing) and one Fulfillment (150+ people)
- Implementation of visual management, pull systems, 5S and daily controls of safety, productivity, quality and cost
- Implementation of weekly scheduling, daily management process, kanban and improvements of quality and productivity
- Maintenance management and improvements (Kaizens), automations and cost reduction initiatives
- Redesign of plant layout to improve production flow, reducing waste and increasing productivity
- Safety mapping and procedures implemented (tagout/lockout, PPE, trainings, RCA, etc)
- Achievements: accidents reduction by 90%; rework reduction from 35% to 4%; throughput increased by 60%; $500k savings in six months; lead time reduction from 14 to 8 weeks.
- Enhanced production efficiency by implementing lean manufacturing techniques and optimizing assembly line processes.
Quality and Continuous Improvement Manager
Biancogres Group (Brazilian top 3 porcelain tile manufacturer)
01.2021 - 01.2022
- Responsible for Quality Management System (product audits and certifications), Continuous Improvement, Customer Service and Quality Control
- Fostering a culture of continuous improvement, prioritizing the appropriate methodologies and tools for problem solving (kaizen, A3, PDCA, DMAIC, 8D, kanban, design thinking, SMED, etc.)
- Carrying out value stream mapping of processes (production, sales, HR, accounts, etc.) to identify opportunities
- Development, management and implementation of improvement project program (cost, quality, productivity, flow, etc.)
- Development competencies and skills in operational teams, with theoretical and practical training approach
- Implementation of the Quality Committee to reduce consumer complaints and costs due to quality escapes
- Implementation of process controls, KPIs and visual management dashboards, sharing and reporting results across the company (production, sales, shipping, quality, customer services, etc.)
- Member of the Base 27 Innovation Hub – seeking innovative solutions to unknown problems
- Achievements: 20% reduction of consumer complaints and 25% of their cost in one year
- Saving R$10,5mi due to improvements projects implemented.
Flexibles Quality Manager
TechnipFMC (Oil & Gas Company)
01.2011 - 01.2021
- Responsible for the Quality Assurance, Quality Control and Continuous Improvements of the Flexible Pipes business in Brazil: 2 industrial plants, 2 logistics bases and 1 R&D Center
- Manager of 80 people across these sites, developing skills and promoting equality and diversity
- Part of the QHSE management network to ensure alignment and prioritization of Global Strategies
- Conduct value stream mapping of processes to identify and prioritize opportunities (cost, quality, productivity, flow, etc.)
- Management and implementation of improvement projects, sharing best practices among the group's plants
- Design and implementation of Lean and Six Sigma model in two plants in Brazil (18 projects implemented)
- Restructuring of the Quality department, optimizing resources and increasing the qualification of the team
- Maintenance of international certifications (management system and product)
- Responsible for customer interface: product inspections, site audits, product quality deviations treatments, lessons learned, correction and improvement plans
- Implementation and monitoring of failure analysis (RCA), routine management, visual management, management of change, risk management, cost of non-quality (CNQ), KPIs, continuous improvement, quality award and lesson learned
- Member of the team responsible for building a new factory in Brazil (definition and implementation of all quality control devices, labs and layouts)
- General Manager of PRODFOR - Integrated Supplier Development and Qualification Program – sponsored by FINDES
- Achievements: Qualification of laboratory to performance material analysis
- ISO 9001, API Q1/17J and Type Approval certification in a new group factory
- Reduction of time with quality processes, as well as 30% reduction of product and management system NCRs
- 25% reduction of CNQ.
Production Manager
Nestlé – Chocolate Garoto (Biggest chocolate factory in Brazil)
01.2000 - 01.2010
- Responsible for planning and production of Chocolates, Tablets (Jumbo) and Candies (600 direct employees)
- Responsible for the implementation of TPM (Leader of the Autonomous Maintenance Pillar) – 14 production lines
- Champion of 22 DMAIC / SMED Projects – R$ 18 million cost reduction in two years
- Project management (PMO) for the purchase/installation of two new lines (Candies and Tablets) in 2009 – international commissioning with suppliers from Germany, Italy and Denmark
- Coordination of the GLOBE project (Nestlé worldwide) – integration of all Nestlé factories (SAP)
- Implementation of Statistical Process Control (CEP) – Variables and Attributes
- Interface with ANVISA (regulatory agency) regarding factory audits and inspections
- Ergonomic studies, layout planning, monitoring and evaluation of times and methods, relays and implementation of labor gymnastics
- Creation and implementation of the 1st Solidarity Campaign (donation of 3 tons of food and more than 500 items of clothing and toys donated to philanthropic institutions in Espirito Santo State)
- Achievements: 24% increase in productivity (OEE), 55% reduction in losses and 20% reduction in consumer complaints for the Tablets lines in two years
- Optimization of costs / productivity: R$ 35 million.
HSE and Production
Aracruz Celulose S.A. – Suzano Group (Biggest paper manufacturer in Brazil)
01.1991 - 01.2000
- Process control and mechanical interventions in general, also working in the areas of hydraulics and pneumatics
- Implementation/management of the Continuous Improvement Program and Program/Planning of resources
- Implementation/management of the Autonomous Maintenance model
- Statistical Process Control (CEP) and Quality Control Program
- Survey and assessment of environmental risks, working at HSE.
Education
Safety Engineering (HSE Post Graduate) -
University of PUC Minas
04.2024
Master in Business -
Federal University of Espirito Santo State
01.2007
Production Engineering (Post graduate) -
Federal University of Espirito Santo State
01.2000
Mechanical Engineering (Bachelor - BSc) -
Federal University of Espirito Santo State
01.1997
Skills
- MS Office (Excel, Power Point, Power BI, Share Point, Teams, Project)
- Acrobat
- Minitab
- Visio
- Bizagi
- Quality Management Systems
Websites
Languages
English
Full Professional
Spanish
Full Professional
Portuguese
Native or Bilingual
Additional Information
Resident at Alpharetta/GA, married, available for travel and visa EB1.
Improvement Courses
- ISO 9001:2015 Lead Auditor, Bureau Veritas, Vitória / ES, 07/2017, 40 h
- TOP-SET Senior Investigator Course, Kelvin TOP-SET, Rio de Janeiro / RJ, 03/2015, 30 h
- Project Management, Compet PM, Vitória / ES, 01/2011, 20 h
- TPM Leader - Autonomous Maintenance Pillar, Nestlé, São Paulo, 04/2009, 40 h
- Green Belt (Seis Sigma) - DMAIC - Problem solving, Verkema, São Paulo, 07/2008, 80 h
Timeline
Manufacturing Director
Nutracap Labs (Dietary Supplements and Cosmetics Manufacturer)
04.2022 - Current
Quality and Continuous Improvement Manager
Biancogres Group (Brazilian top 3 porcelain tile manufacturer)
01.2021 - 01.2022
Flexibles Quality Manager
TechnipFMC (Oil & Gas Company)
01.2011 - 01.2021
Production Manager
Nestlé – Chocolate Garoto (Biggest chocolate factory in Brazil)
01.2000 - 01.2010
HSE and Production
Aracruz Celulose S.A. – Suzano Group (Biggest paper manufacturer in Brazil)
01.1991 - 01.2000
Safety Engineering (HSE Post Graduate) -
University of PUC Minas
Master in Business -
Federal University of Espirito Santo State
Production Engineering (Post graduate) -
Federal University of Espirito Santo State
Mechanical Engineering (Bachelor - BSc) -
Federal University of Espirito Santo State
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