Johnny JJ JHERNANDEZ
El Paso,TX
Summary
Strategic and hands-on engineering executive with 25+ years leading Lean Six Sigma, Kaizen, and Operational Excellence across automotive, industrial, military, medical, and consumer manufacturing. I am known for transforming underperforming operations, eliminating waste, stabilizing processes, and building high-accountability cultures. Career shaped by Japanese manufacturing principles through extensive training at Sumitomo - blending disciplined process control with practical, boots-on-the-floor leadership. Proven ability to lead multi-site capital projects, elevate quality systems, and deliver measurable improvements in safety, throughput, cost, and customer satisfaction.
Engineering Manager and Project Manager with extensive experience in leading engineering, quality, and continuous improvement initiatives within high-volume manufacturing environments. Successfully drove plant-wide transformations aligned with operational excellence and sustainability goals, implementing structured continuous improvement roadmaps that integrated Lean, Kaizen, and Six Sigma methodologies. Achievements include significant reductions in scrap rates and process losses through data-driven analysis and enhanced quality systems. Proven track record in managing major capital projects, mentoring technical teams, and aligning plant performance with corporate initiatives.
Overview
32
32
years of professional experience
Work History
Engineering Manager / Project Manager
Southwire Company
El Paso, USA
01.2022 - Current
- Lead engineering, quality, and continuous improvement strategy for a high-volume wire and cable manufacturing facility.
- Drive plant-wide transformation aligned with Southwire's Operational Excellence and sustainability goals.
- Built and deployed a structured CI roadmap integrating Lean, Kaizen, and Six Sigma tools across production, quality, and maintenance.
- Reduced scrap and wire breaks through DOE, root-cause analysis, and process standardization.
- Strengthened quality systems by elevating inspection standards, revising control plans, and coaching quality teams on structured problem-solving.
- Led major capital projects including line upgrades, equipment installations, and safety improvements.
- Implemented engineering KPIs, visual management, and daily accountability routines to improve responsiveness and ownership.
- Mentored engineers and technicians, developing a culture of urgency, discipline, and continuous improvement.
- Partnered with corporate CI leaders to align plant performance with enterprise-level initiatives.
Sr. Manufacturing Engineer / Project Manager
Sumitomo Electric Wiring Systems
El Paso, USA
01.2010 - 01.2021
- Eliminated 100% of PVC compounding scrap due to pellet agglomeration within first month.
- Led multi-million-dollar equipment transfers, installations, and commissioning projects.
- Developed production, quality, and safety standards that significantly reduced process losses.
- Installed automatic color-change systems and upgraded extrusion take-up systems.
- Deep immersion in Japanese Lean, Kaizen, and Six Sigma methodologies.
Production Manager / Engineering Manager
Flexaust Inc.
El Paso, USA
01.2007 - 01.2010
- Directed engineering, production, quality, and maintenance teams.
- Led complete transfer of multiple production lines to China, including installation, validation, and training.
- Implemented new test fixtures, gauges, and capital equipment to improve value streams.
Sr. Product Design Engineer / Manufacturing Process Engineer / Quality Manager
Flexaust Inc.
El Paso, USA
01.2001 - 01.2007
- Designed injection-molded and extruded products for automotive, industrial, medical, and military applications.
- Improved processes using SPC, DOE, DFMEA, PFMEA, and time studies.
- Created APQP documentation, PPAPs, control plans, and quality systems.
Product Engineer
Honeywell Sensor Systems
El Paso, USA
01.1998 - 01.2001
- Designed potentiometers and metal stamping components.
- Improved customer service by 120% through 8D corrective action leadership.
Manufacturing Process Engineer
Gould Shawmut Inc.
El Paso, USA
01.1994 - 01.1998
- Led transfer of medium-voltage fuse assembly lines to Juarez.
- Implemented capital equipment, improved run rates, and strengthened ISO systems.
Education
BS - Mechanical Engineering
University of Texas at El Paso
El PasoSkills
- Lean Six Sigma Black Belt
- Kaizen Leadership
- 5S Deployment
- Operational Excellence Strategy
- Waste Elimination
- Value Stream Optimization
- DOE
- SPC
- PFMEA
- DFMEA
- APQP
- PPAP
- ISO9000
- QS9000
- Multi-Site Project Leadership
- Capital Equipment Transfers
- Engineering & Maintenance Leadership
- Process Stabilization
- Cultural Transformation
- Coaching & Talent Development
- Continuous improvement
- Lean methodologies
- Six Sigma
- Project management
- Equipment installation
- Production optimization
- Visual management
- APQP documentation
- Key performance indicators
- Capital project execution
- Engineering project management
- Process standardization
- Root cause analysis
- Kaizen methodology
- Lean manufacturing
Languages
- Spanish
- English
- Spanish
Core Leadership Strengths
- Lean Six Sigma Black Belt
- Kaizen Leadership
- 5S Deployment
- Operational Excellence Strategy
- Waste Elimination
- Value Stream Optimization
- DOE / SPC / PFMEA / DFMEA
- APQP / PPAP / ISO9000 / QS9000
- Multi-Site Project Leadership
- Capital Equipment Transfers
- Engineering & Maintenance Leadership
- Process Stabilization
- Cultural Transformation
- Coaching & Talent Development
Timeline
Engineering Manager / Project Manager
Southwire Company
01.2022 - Current
Sr. Manufacturing Engineer / Project Manager
Sumitomo Electric Wiring Systems
01.2010 - 01.2021
Production Manager / Engineering Manager
Flexaust Inc.
01.2007 - 01.2010
Sr. Product Design Engineer / Manufacturing Process Engineer / Quality Manager
Flexaust Inc.
01.2001 - 01.2007
Product Engineer
Honeywell Sensor Systems
01.1998 - 01.2001
Manufacturing Process Engineer
Gould Shawmut Inc.
01.1994 - 01.1998
BS - Mechanical Engineering
University of Texas at El Paso