Luis Alberto Quan
Laredo,USA
Summary
Dynamic Plant Manager with a proven track record at Lear Corporation, excelling in lean manufacturing and continuous improvement. Achieved a remarkable increase in efficiency, while fostering team development and quality assurance practices. Bilingual in English and Spanish, I am committed to driving operational excellence and enhancing productivity in fast-paced environments.
Overview
32
32
years of professional experience
4
4
Certifications
Work History
Southern Sites Plant Manager
Sanoh America
Scottsboro, AL
12.2023 - 08.2025
- Responsible for 5 manufacturing sites and 450 peoples, in TN, AL and MS.
- Responsible for the turnaround of the plants, increasing OEE from 32% to 56% in a year reducing downtime by 40%.
- Achieve L1 (higher level) in Nissan quality scorecard coming from L4 (lower level).
- Stabilize the inventory control and improve the physical inventories results by $900k.
- Training and implement 'problem solving methodology' getting improvements reducing downtime and absenteeism from 10% to 3%.
- Improving efficiency from 48% to 85% during the first year.
- Implementation of the weekly cycle count control to reduce the lost in the inventories and increase the accuracy. Reduction in 40% of the losses in the first year.
- Reduction of the OT in 30% through improvement of the OEE and hourly output with hourly control and time studies to improve the use of the machines.
- Responsible for P&L, responsible for Quality, Maintenance, Engineering, Purchasing, Business Managements, Finance, Human Resources, Logistics, Operations, 8 directs report.
Plant Director
Novares
Janesville, WI
03.2023 - 12.2023
- Responsible for a 150,000 Ft2 with 25 employees, working 24/7. Plant with 14 Injection Molding Machines, 45 final assembly cells and sales US$ 80M per year.
- Responsible for P&L, responsible for Quality, Maintenance, Engineering, Purchasing, Business Achievements Managements, Finance, Human Resources, Logistics, Operations.
- Achievements:
- Stabilization of labor efficiency above 65% in 3 months.
- IATF and Q1 certification action plan.
- Reduce PPM to 6. On target.
Plant Manager
Aptiv - ESD
Troy, USA
06.2019 - 02.2023
- Responsible for managing a facility of 222,000 ft2 with 3,100 employees (direct, indirect, and salaried staff) and US$300 millions in sales per year.
- Responsible for P&L, budgeting, Leading plant's management team and defining strategies to the overall success performance of the plant.
- Responsible for Quality, engineering, Maintenance, Facilities, Human Resources, Manufacturing, Customer Relationships, Regional Support Coordination.
- Ensure safety of employees at the workplace, responsible for the implementation of the best corporate practices in order to standardize the operation worldwide.
- Achievements:
- Stabilization of labor efficiency from 65% to 80%.
- Q1 Ford preparation.
- Reduction of IPPM's to less 20,000.
- Prepare the plant for Tesla Model Y and Model 3 launch. Responsible for RC1, RC2 prototypes in order to be ready to start production in January 2020.
Plant Manager
Lear Corporation
Lapu Lapu City, Philippines
04.2016 - 05.2019
- Oversaw management of 134,000sf facility housing 827 employees, including direct, indirect, and salaried staff, with annual sales of US$ 140 million.
- Oversaw P&L and budgeting to enhance financial performance of plant.
Led management team to define and implement strategies for operational success.
Developed strategic initiatives that improved overall productivity and efficiency.. - Responsible for Quality, Engineering, Maintenance, Facilities, Human Resources, Manufacturing, Customer Relationships, and Regional Support Coordination.
- Guarantee workplace safety for employees, charged with implementing leading corporate strategies to unify worldwide operations.
- Achievements:
- Exceed the percentage of OI% (2%) during my three years as plant responsible.
- Dramatically reduced the plant's overtime during my three years in my current position from 24% to 10%.
- Reduction from 120,000 ippms to 9,000 ippms.
- Single Digit for DPPM's.
- CT-PAT certification by US Customs.
- IATF certification with 0 NC.
- Regional Award for Best Plant in safety.
- Saving for US$ 1.2 millions in continuous improvement.
- Successful Financial Operation Audit - FOA 2016.
Continuous Improvement & Launch Manager
LEAR CORPORATION - E-Systems
Kabinburi, Thailand
07.2014 - 03.2016
- Responsible for improvement in process and efficiency, reduction of IPPM's, DPPM's, transfer the GM Programs to new facility, Model Year change, efficiency improvements.
- Responsible and accountable for continuous for supporting all physical engineering needs of Production Control.
- Analyze and improve material flow processes with a focus on manpower planning and standardized work.
- Responsible for managing and submitting general improvement and efficiencies across the Company's products, systems, operations and processes.
- Work with the Senior Management Team, developing, setting the pace and implementing business transformational and continuous improvement strategies with sensitivity towards the organizational structure, commercial approach, culture, people and processes.
- Became an expert in lean methodologies with a green belt certification.
- Coached trained and assessed groups of team members periodically.
- Responsible to coordinate Customer Satisfaction Issues, Material Variation Issues, Internal Defects Issues, Cost Driver Issues and Plant's Efficiency, and Lean Implementation.
- Process improvements; the development of new projects, implementation of best practices and search of innovations as well as improvement of quality strategies.
- Achievements:
- Certification 10 greens Belts in 1 year.
- Faster growth for new program in Asia.
- Ippm's below of corporative target by 1,000.
- Single Digit for DPPM's.
- Successful transfer for X61 program from Philippines to Thailand.
- Successful transfer for GM program with zero downtime.
- Saving for US$ 900k in continuous improvement.
Operations Manager Wiring Plant GM Plant
LEAR CORPORATION - E-Systems
Kabinburi, Thailand
11.2012 - 07.2014
- As an operations Manager was responsible for overseeing production, managed planning and scheduling on a daily basis for a plant of 700 employees.
- Was responsible for the organizing and overall directing medium and long terms methods and procedures relating to overall operations.
- Defined plant layout, working areas and production flow, aisles, safe areas, etc., ensured said areas were kept properly identified and signalized.
- Established and kept in operations 5S.
- Established and kept in operation, Safety and Health, and waste management rules and procedures.
- Development of the local manufacturing team.
- Achievements:
- Successful implementation 2013 new model year.
- Reduction ippm's from 55,000 to 4,000.
- Best New Line Launch 2014.
- Best Implementation Lear Base Capacity to program weekly production.
- 98% Schedule attainment.
Plant Manager
LEAR - KYUNGSHING
San Pedro Sula, Honduras
08.2009 - 10.2012
- Responsible of managing 600 people, in three shifts.
- Increased the plant efficiency from 90% to 101%, in five years Tela plant only 5 had customer issues, producing 550 set of harnesses per day.
- I was able to run at 105% of efficiency, 5`000 ippm exceeding corporate target which was 8,500 ippm.
- Managed a team of 8 engineers in quality, 1 HR, 8 productions supervisors, 3 product engineers.
- In my second period in Tela plant, I was Face Lift responsible, transition from 2009 to 2011-year model.
- I was requested back to Tela Plant by specific customers (Hyundai Montgomery Motors in Alabama US.) to ensure the all-around successful launch for the face lift of 2010 Santa Fe SUV.
- We had zero issues in quality, engineering, and delivery.
Regional Materials Manager
LEAR KYUNGSHING
San Pedro Sula, Honduras
08.2008 - 08.2009
- Material control, physically inventories, cycle counts, manage an inventory of US$ 13.5 millions of dollars.
- Under my administration was the first time that a physically inventory result positive, recovering the lost from the last physically inventory.
- Obsolete material reduction control.
- Coordination of raw material containers from Korea, Europe and Mexico to the plant, coordinating and expediting in order to reduce the arriving time to the plant.
- Coordinate with corporative purchasing the acquisition of raw material from suppliers.
- Achievements:
- Inventory accuracy 98%.
- Perfect implementation for new methodology for physically inventories.
Plant Manager
LEAR - KYUNGSHING
San Pedro Sula, Honduras
04.2003 - 08.2008
- Responsible to manage 450 people, in three shifts.
- Increase the plant efficiency from 27% to 98% (design efficiency) in a record time into Lear Mexican Operation, the launch of the plant was record in Lear Mexican operation in regards quality, growth, delivery, minimizing the shutdown risk in the assembly plant in the launch process, producing 550 set of harnesses per day.
- Regarding quality, the plant kept 5`000 ippm, better than corporative goal which is 8,500 ippm.
- Managing a staff of 8 engineers in the quality department, 1 HR, 8 production supervisors, 3 product engineers.
- Achievements:
- 5 Start certification - Hyundai Quality certification. 1st plant in America in obtain this certification.
- Perfect Launch Plant.
- Faster Growth Efficiency plant.
Plant Manager
FINOTEX
Choloma, Honduras
01.2002 - 04.2003
- I started up this plant and achieving 90% efficiency in 9 months, managing 400 people in three shifts, and reducing the lead time from 15 day to 7 days, increased production from 1 million meters printed per month to 5-millions of printed meters per month. AQL 1.5%.
- Installation of 40 mills for label tape and producing 5,000 yards per week.
- Provided support for the turnover of the Barranquilla Plant, in Barranquilla, Colombia.
- Achievements:
- Set up the first label-tape plant in Honduras.
- Improved the rolled system in the circular printers increasing the production 125%.
- Label Tape & Flexographic Plant.
Manufacturing Manager
Paxar de Honduras
Villanueva, Honduras
02.1999 - 12.2001
- In charge of coordinating the production floor for a plant of 450 employees working 3 shifts.
- I was the link between production, planning, and manufacturing.
- Responsible for coordinate 10 rotary printers with 6 colors, 25 ultrasonic cutter machines, 10 heat transfer printers.
- Achievements:
- Improved the AQK from 5% to 1.5% plant wide.
- Reduced the lead times from 8 working days to 5 working days.
- Responsible for the installation of Mark Andy offset printer.
- Reduced 20% of overtime.
- Increased the efficiency to 98% with 90% OEE.
- Improved the preventive maintenance reducing the idle time per machine in 25%.
Operations Manager
Hondutex - Ligget de Honduras
Choloma, Honduras
08.1997 - 02.1999
- Responsible for operating a plant with 630 operators working in 4x4 schedule, 7 days per week, producing 8,000 dozens t-shirts, with an AQL 1.5%.
- Achievements:
- Successful implementation of the 4x4 working schedule (pioneered in Honduras this type of system).
- Reduced the lead time to complete an export container from 3 days to every 18 working hours.
- Achieve 110% efficiency plant wide.
Operations Manager Assistance
Sulatex - Ligget de Honduras
Choloma, Honduras
05.1995 - 08.1997
- Responsible for operate a plant with 630 operator working in 4x4 schedule, 7 days a week, producing 8,000 dozens t-shirts, with an AQL 1.5%.
- Achievements:
- Successful implementation of the 4x4 working schedule, (pioneered in Honduras this type of system).
- Reduced the lead time to complete an export container from 3 days to every 18 working hours.
- Achieved 110% efficiency plant wide.
- Implemented the training center concept and team system production.
Engineering Manager Assistance
Ligget de Honduras
Choloma, Honduras
01.1994 - 04.1995
- Key player in the startup of the plant, developing the training center previous to sewing team, in charge of leading the training for new employees.
- Responsible of elaborating learning curves per operation and follow up according with AMT - Analytic Method of Training.
- Achievements:
- Training Center Center Implementation.
- Design Lay out of the plant.
- Toyta production teams implementation.
- Kurt Salmon Associated - KSA certification for supervisors.
- AMT certification.
- AQL 2.5%.
- Hanes Brand Quality certification.
Quality Auditor
Compania Hulera Sula
San Pedro Sula, Honduras
03.1993 - 12.1993
- Quality Auditor responsible quality control of the process for plastic injection module. steam press module and elaborated the sample report per batch during my shift.
- Achievements:
- Reduced the incidence of defects in steam press modules in 25%, allowing production to increase the output and reduce the overtime.
- AQL 2.5%.
Education
BS - INDUSTRIAL ENGINEERING
Centro Universitario Regional Del Norte - CURN
San Pedro Sula, Cortes, Honduras08.1995
AA - Industrial Engineering Technology - Thermodynamics
Miami Technical College
Miami, FL12.1985
Skills
- Bilingual – English and Spanish
- Lean manufacturing certification
- Six Sigma Green Belt
- ISO 9000 compliance
- IATF-16949 standards
- Continuous improvement implementation
- Team coaching and development
- Time and method engineering
- Job instruction design
- Quality assurance practices
- Inventory management
- KSA certification
- AAMT certification
- Cutting label machinery certification
- Printing label equipment certification
- 5S methodology
- Microsoft Office proficiency
- Lotus Smart Suite expertise
- Email communication skills
- Flexography printing techniques
- Tape loom operation
- Label manufacturing certification
- Bulletproof manager training
Additional Skills And Certifications
- Bilingual - English and Spanish
- LEAN Manufacturing Certified
- Six Sigma
- Green Belt Certification
- ISO 9000
- IATF-16949
- Continuous Improvement philosophy implementation
- Team Coaching
- Time & Method Engineering
- Job Instruction development
- Quality Assurance
- Inventory Control Management
- KSA Certified
- AAMT Certified
- Cutting Label Machines Certified
- Printing Label Equipment Certified
- 5's
- Microsoft Office
- Lotus Smart suite
- Flexography Printing - Rotary Label
- Tape Looms Printing
- Label Manufacturing Certified
- Bullet Proof Manager Training
- Experience in manufacturing of Garments, time studies, costing
- Experience in manufacturing of Rubber and plastic products, footwear, automotive parts
Languages
English
Full Professional
Spanish
Full Professional
Certification
Lean Manufacturing
Timeline
Southern Sites Plant Manager
Sanoh America
12.2023 - 08.2025
Plant Director
Novares
03.2023 - 12.2023
Plant Manager
Aptiv - ESD
06.2019 - 02.2023
Plant Manager
Lear Corporation
04.2016 - 05.2019
Continuous Improvement & Launch Manager
LEAR CORPORATION - E-Systems
07.2014 - 03.2016
Operations Manager Wiring Plant GM Plant
LEAR CORPORATION - E-Systems
11.2012 - 07.2014
Plant Manager
LEAR - KYUNGSHING
08.2009 - 10.2012
Regional Materials Manager
LEAR KYUNGSHING
08.2008 - 08.2009
Plant Manager
LEAR - KYUNGSHING
04.2003 - 08.2008
Plant Manager
FINOTEX
01.2002 - 04.2003
Manufacturing Manager
Paxar de Honduras
02.1999 - 12.2001
Operations Manager
Hondutex - Ligget de Honduras
08.1997 - 02.1999
Operations Manager Assistance
Sulatex - Ligget de Honduras
05.1995 - 08.1997
Engineering Manager Assistance
Ligget de Honduras
01.1994 - 04.1995
Quality Auditor
Compania Hulera Sula
03.1993 - 12.1993
BS - INDUSTRIAL ENGINEERING
Centro Universitario Regional Del Norte - CURN
AA - Industrial Engineering Technology - Thermodynamics
Miami Technical College