MANUEL VALENTE AGUERO
Northampton,PA
Summary
Operations and production leader with 32+ years in continuous-process cement manufacturing, delivering improvements in output and cost reduction. Directed optimization of kiln and mill systems and increased alternative-fuel utilization for measurable efficiency and quality gains. Strengthened safety and compliance through standard work, process discipline, and team performance management.
Overview
2
2
Languages
1
1
Certification
33
33
years of professional experience
Work History
Production Manager
AMRIZE
Whitehall, PA
11.2024 - Current
- Led production department with 35 employees to meet output goals while upholding safety, environmental, quality, and operational standards.
- Facilitated daily production activities to achieve targeted product volumes while ensuring safety, environmental, and quality standards were met.
- Managed kiln and finish mill operations to improve productivity, reliability, and product quality.
- Monitored production results and ensured adherence to established quality parameters.
- Delivered safety training and reinforced safe operating practices across production organization.
- Managed refractory planning, budgeting, and execution to support reliable kiln operations.
- Revised plant procedures and operating standards to improve consistency and accountability.
- Supported continuous improvement efforts focused on productivity, equipment performance, quality, and cost.
- Coordinated operational priorities and resources to enhance overall plant performance.
Optimization Manager
ASH GROVE CEMENT
Seattle, WA
07.2023 - 08.2024
- Provided operational optimization leadership for a 0.75 MMTPY cement manufacturing facility, focusing on production efficiency, process reliability, safety, quality and cost performance.
- Increased alternative-fuel substitution by 24%, improving fuel flexibility and operating economics.
- Enhanced kiln operating performance through targeted process optimization and operator coaching.
- Increased cement mill production through operational improvements.
- Reduced kiln stoppages from refractory issues by enhancing planning and execution.
- Streamlined operational procedures to strengthen process consistency.
- Implemented new refractory projects, including cooler tube applications.
- Monitored plant process performance, production KPIs and operating indicators.
- Prepared and monitored production KPIs, daily reports and operating procedures.
- Developed and monitored training plans for production personnel.
- Coordinated refractory installation activities during kiln outages.
- Supported employee health and safety initiatives.
- Monitored environmental parameters and emissions for regulatory compliance.
- Ensured compliance with product quality parameters and manufacturing standards.
- Updated plant procedures to improve operational consistency and productivity.
Production Manager
ASH GROVE CEMENT
Seattle, WA
07.2018 - 07.2023
- Managed production operations for a 0.75 MMTPY cement manufacturing facility with approximately 40 employees, with responsibility for production, safety, quality, cost, environmental compliance and workforce development.
- Increased alternative-fuel substitution from 9% to 20%.
- Reduced refractory consumption by up to 10% annually through improved refractory selection, installation and operating practices.
- Reduced fuel and power consumption by approximately 5% through kiln optimization.
- Improved clinker quality and process stability.
- Increased cement mill production by approximately 5%.
- Implemented 1L cement utilization with up to 13% limestone substitution.
- Cultivated 5S and housekeeping culture, enhancing organization and workplace safety across production operations.
- Optimized quality parameters, including C3S, to improve kiln and finish mill efficiency.
- Executed refractory improvement projects, optimizing drop-out sections, kiln brick designs, 5th-stage roof, and 4th-stage thimble for increased operational efficiency.
- Directed production activities and resources to meet plant production targets.
- Prepared and monitored production budgets covering fixed and variable costs.
- Managed production forecasts and operating plans.
- Managed employee safety and reinforced safe operating practices.
- Planned refractory installation activities for kiln outages.
- Developed training plans and coached production employees.
- Monitored environmental parameters and emissions.
- Ensured finished products met established quality specifications.
- Worked cross-functionally with commercial and operational teams to align production requirements.
Operations Manager
CEMEX PUERTO RICO
Ponce, Puerto Rico
01.2014 - 01.2017
- Led operations for a 1.3 MMTPY cement manufacturing plant with approximately 180 employees, with broad accountability for production, operational performance, safety, cost, labor relations, quarry operations and continuous improvement.
- Delivered $6M in annual fixed-cost savings.
- Reduced variable costs by 15% through operational optimization and cost-control initiatives.
- Reduced working capital by $4M.
- Outsourced quarry operations, enhancing operating economics and efficiency.
- Negotiated a collective bargaining agreement delivering approximately $1M in annual savings.
- Doubled accident-free days through improved safety focus and employee engagement.
- Increased finish mill efficiency by 20%.
- Applied 5S, DILO, Kaizen, and Bank of Ideas methodologies to streamline operations.
- Cultivated cost and operational accountability culture, driving performance and engagement.
- Reduced process waste through systemic management and continuous improvement.
- Developed internal equipment capabilities for refractory installation, scaffolding and other specialized activities.
- Directed overall plant operations, production performance and resource deployment.
- Established key metrics for production and maintenance performance.
- Managed employee health and safety initiatives.
- Led workforce training and development programs.
- Supported quarry mining plans and ensured alignment with plant requirements.
- Worked closely with commercial, logistics and planning organizations.
- Led labor relations and collective bargaining activities.
- Implemented operational improvements to increase productivity and control costs.
Production Manager
CEMEX DOMINICANA
San Pedro de Macoris
01.2008 - 01.2013
- Managed production for a 1.8 MMTPY cement manufacturing plant with approximately 105 employees, overseeing production performance, quality, safety, cost and workforce development.
- Managed daily operations of production department and workforce resources.
- Prepared and monitored production budgets and variable costs.
- Established KPIs for production monitoring and performance control.
- Managed employee safety and operational compliance.
- Developed training plans for production personnel.
- Improved product quality standards and process consistency.
- Increased cement additive usage, enhancing product performance and sustainability.
- Implemented whole tire alternative fuels in kiln operations, reducing environmental impact and improving energy efficiency.
- Lowered costs by analyzing and improving operational efficiencies by 10%.
- Developed and implemented operating procedures, streamlining manufacturing processes and enhancing overall efficiency.
- Reduced quarry process variability and improved operational consistency.
- Ensured finished product quality parameters were consistently achieved.
- Collaborated with commercial and logistics functions to support operational requirements.
Production Manager
CEMEX VENEZUELA
Pertigaleta
01.2000 - 01.2008
- Managed production operations for 65 employees in large-scale cement manufacturing, overseeing production planning, cost management, safety compliance, personnel development, equipment performance, process improvements, and environmental standards.
- Achieved high-production records for clinker and cement.
- Managed fixed and variable departmental costs.
- Prepared and monitored production plans and budgets to align with operational goals and optimize resource allocation.
- Optimized operational equipment and manufacturing processes.
- Implemented self-managed, high-performance operational teams.
- Supervised operational team leaders and production personnel.
- Managed safety performance for operational personnel.
- Ensured compliance with environmental and operational regulations.
- Supported development of specialized cement products for oil-well applications.
- Aligned plant operations with quarry exploitation and production plans.
- Participated in quarry optimization initiatives to extend useful quarry life.
- Developed training plans to enhance skills and knowledge of management and operations personnel, fostering a culture of continuous improvement.
Process Engineer
CEMEX VENEZUELA
Maracaibo
01.1994 - 01.2000
- Provided process engineering and operational support for calcination, grinding and cement manufacturing systems.
- Increased mill output through process optimization.
- Increased kiln production by approximately 5% on average.
- Reduced variable operating costs by approximately 10%.
- Evaluated calcination and grinding systems, identifying opportunities for process improvements.
- Monitored operating parameters and process performance.
- Developed and implemented operating procedures.
- Coordinated refractory maintenance activities, ensuring optimal kiln operations.
- Scheduled production shifts and workforce assignments.
- Trained personnel in process and operational skills, enhancing team competency and operational effectiveness.
Education
MBA -
Universidad de Oriente
Barcelona, VenezuelaBachelor of Science - Chemical Engineering
University Simon Bolivar
Caracas, VenezuelaSkills
- Manufacturing Operations Leadership Production Management Plant Operations 24/7 Continuous-Process Manufacturing Workforce Leadership Production Planning Production Scheduling KPI Management Cost Control Budget Management Labor & Resource Utilization Raw Material Management Finished Product Quality Process Optimization Equipment Efficiency Downtime Reduction Continuous Improvement Lean Manufacturing 5S Kaizen Autonomous Maintenance Root Cause Analysis Corrective Actions Safety Management Environmental Compliance Regulatory Compliance Employee Training & Development Change Management Cross-Functional Leadership Operational Troubleshooting Process Engineering SAP / ERP ISO 9001 ISO 14001 MSHA EPA
- Production and Plant Operations
- Production planning Production scheduling Continuous-process manufacturing Kiln operations Cement mills Raw materials Finished product quality Equipment utilization Process reliability Downtime reduction Production forecasting
- Leadership & Workforce Development
- Production team leadership Supervisor development Employee coaching Training plans Performance management Workforce planning High-performance teams Safety training Change management Labor relations Cross-functional collaboration
- Continuous Improvement
- Lean Manufacturing 5S Kaizen DILO Autonomous Maintenance Bank of Ideas Process Optimization Waste Reduction Root Cause Analysis Corrective Actions Standard Operating Procedures Operational Excellence
- Cost & KPI Management
- Production budgets Fixed and variable costs Cost reduction Labor/resource utilization Material usage Production KPIs Quality KPIs Efficiency metrics Equipment performance Process indicators Forecasting Expenditure control
- Safety, Quality & Compliance
- Safety management Environmental compliance MSHA EPA ISO 9001 ISO 14001 Quality parameters Emissions monitoring Regulatory compliance Safe operating practices Refractory safety Process controls
- Systems & Software
- SAP JD Edwards Microsoft Excel Microsoft Word Microsoft PowerPoint Bentley
- Production scheduling
Personal Information
Title: Production Superintendent | Production Manager | Manufacturing Operations Leader
Certification
- Congress Refra Kolloquium Berlin, 2008
- Specialist in Milling and Drying Operations Operum / CEMEX, Mexico, 19961997
- Process Training Cementos Nacionales Plant, Dominican Republic, 1998
- International Development Dimensions Facilitator, 2000
- MSHA / EPA Regulatory Knowledge
- ISO 9001 / ISO 14001
- Lean / 5S / Kaizen / Autonomous Maintenance
Accomplishments
- Managed production operations for cement plants ranging from 0.75 MMTPY to 1.8 MMTPY.
- Led operational organizations of up to 180 employees, with accountability for production, safety, quality, cost and productivity.
- Delivered $6M in annual fixed-cost savings and 15% reduction in variable costs at CEMEX Puerto Rico.
- Reduced working capital by $4M through operational and sourcing improvements.
- Negotiated a collective bargaining agreement delivering approximately $1M in annual savings.
- Improved finish mill efficiency by 20% through process optimization.
- Increased alternative-fuel substitution from 9% to 20% and subsequently achieved an additional 24% AF substitution improvement.
- Reduced refractory consumption by up to 10% annually while improving kiln reliability.
- Reduced fuel and power consumption by approximately 5% through kiln optimization.
- Increased cement mill production by approximately 5%.
- Achieved significant improvements in clinker quality and production performance.
- Doubled accident-free days through stronger safety practices and employee engagement.
- Implemented 5S, Kaizen, DILO, Bank of Ideas and autonomous maintenance initiatives.
- Developed high-performance, self-managed operational teams and strengthened accountability.
- Implemented alternative fuels, cement additives and new refractory technologies to improve productivity and reduce cost.
Languages
English
Full Professional
Spanish
Native/ Bilingual
Timeline
Production Manager
AMRIZE
11.2024 - Current
Optimization Manager
ASH GROVE CEMENT
07.2023 - 08.2024
Production Manager
ASH GROVE CEMENT
07.2018 - 07.2023
Operations Manager
CEMEX PUERTO RICO
01.2014 - 01.2017
Production Manager
CEMEX DOMINICANA
01.2008 - 01.2013
Production Manager
CEMEX VENEZUELA
01.2000 - 01.2008
Process Engineer
CEMEX VENEZUELA
01.1994 - 01.2000
MBA -
Universidad de Oriente
Bachelor of Science - Chemical Engineering
University Simon Bolivar