Robert Asencio
Schertz
Summary
Dynamic Plant Manager with a proven track record at 48Forty Solutions, leveraging Lean Manufacturing and Six Sigma methodologies to drive operational excellence. Skilled in SAP and fostering team engagement, I successfully increased productivity by 10% while enhancing safety standards and compliance across all departments.
Overview
28
28
years of professional experience
Work History
Plant Manager
48Forty Solutions
San Antonio
05.2025 - Current
- Responsible and accountable for the plant P&L.
- In charge of the Production, Quality, Maintenance and Shipping Departments.
- Manage the work of all 45-55 production employees oversees production and shipping schedules based on availability of raw and finished goods
- Provide hands-on leadership as a working manager, responsible for mentoring and coaching all employees and managing employee relations issues
- Support plant administration to ensure compliance to established policies
- Assist with the entire new hire process with dedicated Recruiter and Onboarding Team in HR, and make all employment decisions within the plant
- Consult with the General Manager for the cost and yield performance of the Plant
- Support and implement cost control initiatives and process control within the Plant
- Continually review operations activities, including local transportation activities to maintain compliance with all Federal, State and local laws (OSHA, DOL, DOJ, EPA, FD)
- Drive Safety improvements across the Plant
- Ensure the consistent execution of all SOPs throughout the Plant. accordance with the PMS Commercial Organization, Global Supply Chain
- Deliver best operational practices and cost efficiencies across the Plant while maintaining critical quality and raw material utilization standards that are necessary to maintain customer satisfaction and Plant profitability
- Implement and manage Lean opportunities to effectively eliminate waste
- Provide leadership to Plant staff to effectively recruit, train, develop, evaluate, motivate, delegate and monitor their activities
- Drive efficiencies in asset utilization through proper transportation scheduling, dispatch, & driver management while meeting customer expectations
- Pallet repair and Reman
Plant / OPS Manager
Pedal Point Recycling
San Antonio
10.2023 - 03.2025
- Responsible for a workforce of 45 people with direct supervision of Production Manager, Maintenance/ Engineer Manager, Logistics Manager and Safety / Quality Manager.
- Direct accountability for the hub P&L results.
- Active role on auditing the shop floor to make sure the scheduled plan has been executed.
- Help and support team leadership to achieve the plant goals.
- In charge of Shipping and Receiving with direct responsibility on Inbounds and Outbounds (scheduling, planning and ERP)
- Champion new safety and quality initiatives to improve site culture.
- Support and coordinate preventive maintenance programs to ensure equipment reliability.
- Engaged and lead continuous improvement programs – Kaizen events, 5’S, Visual aids.
- Promote team building and employee “voice the customer “ in order to increase people engagement to all levels.
- ISO 9001 internal audit supports compliance with regulations.
- Implement Zero Accident program with proper training and documentation.
- Document and reporting all plant KPI’s and communicate on corporate meetings.
- Lead by example and teach / train leadership in the various company areas.
- Recycling of E-Waste
Plant Manager
Red River Brick
Schertz
07.2021 - 10.2023
- Responsible and accountable for the plant P&L.
- In charge of the Production, Quality, Maintenance and Shipping Departments.
- Champion Lean Manufacturing Activities for the Overall Plant Improvements Program
- Provide the team with weekly reports and monthly “Get together at the breakroom “to discuss plant status in all aspects.
- Support initiatives for our Zero Accidents Safety Program.
- Provide upper management with accurate company reports at all levels on a timely manner.
- Provide proper training programs for my leadership in order to sustain proper process standardization.
- Generate employee engagement program to promote high end morale within the team (lunches, safety initiatives, safety rewards, productivity goal achievements).
- Improve Environmental standards for the utility’s consumption, trash disposal and recycling.
- Increase productivity by 10% using lean techniques, eliminating roadblocks, and identifying bottlenecks in the processes.
- Implement TPM with EEO in our equipment and machines resulting in 20% less downtime.
- Increase shipments from our yard from 15 trucks per day to 30 trucks per day.
- Brick, Paver, Concrete, Aggregates Manufacturer
Operations Manager
Quikrete
San Antonio
04.2018 - 07.2021
- Lead Champion for Lean Manufacturing implementation on Cost reduction, Volume increase and Quality Standards.
- Positioning manpower strategically through the identification of key role positions, proper cross training, hours utilization vs productivity and the use of automation processes.
- Accomplish company KPI’s and raise the bar for the stretch corporate goals.
- Support and implement effectively the company Safety Vision Zero program throughout monthly training, floor audits and Improvement programs.
- Decrease Reclaim volume by more than 10% with proper check sheets and batch making program improvements.
- Train, Develop and Coach Leadership for the different key positions on Operations.
- Set FIFO and Kanban systems for receiving of raw materials and finish good products.
- Champion Visual Management Implementation throughout the plant.
- Lead daily communications meetings in the mornings and afternoons to pass key information and follow up of actions with the teams.
- Effectively promote leadership within the company.
- Develop and implement a planning tool with a one-week length of production forecast based on sales.
- Provide free lunches or extra PTO’s hours when team meet set expectations as a motivational tool.
- Sand, Rock, Gravel, Cement Powder, Aggregate Manufacturer
Operations Manager
DAP Inc
Dallas
09.2016 - 04.2018
- In charge of 150 employees for the Compounding, Packaging, and Support Groups Departments.
- Made manpower adjustment based on product demand, equipment optimization and scheduling projections to optimize labor cost.
- Direct Daily communication meetings to provide performance results of operations based on plant KPI’s (safety, Quality, Service, Cost) and integrate all groups to continuous improvement action plans.
- Implement Target Zero program successfully resulting in less incidents reports and No Recordables after implementation.
- Identify and champion several cost reduction projects based on KAIZEN methodology to bring up quick financial results. Packaging projects resulted in a 25% cost improvement.
- Work together with Quality and Maintenance manager in FMEA and Fishbone techniques and eliminate and solve root cause issues improving Quarterly First Time Rights from 87% to 93% meeting business goal.
- Coordinate all scheduling and planning activities to ensure required safety stock levels and ensure fill rates to our customers with over 99% of expectation.
- Promote and monitor safety housekeeping and good manufacturing practices throughout the plant at all levels.
- Coach and train managers and supervisors in SAP systems and Inventory management.
- Support actively yearly warehouse inventory in all phases. This is including training, equipment, support groups and area preparation.
- Achieved productivity goals in Operations in fiscal year 2017.
- Improve OEE of plant equipment through Total Maintenance Program and optimizing Preventive Maintenance and minimizing Downtime in equipment’s.
- Adhesive & Specialty Chemicals Manufacturer
Production Manager
Mapei
Garland
08.2012 - 08.2016
- Responsible for the Daily Planning based on orders and Min / Max per SKU’s.
- Coordinate delivery of orders with priority list by carrier with Shipping Department.
- Achieved over 99.5% On Time Delivery Service on direct customers and intercompany orders.
- Generate new program for 5’S in Liquids and Pastes Department with clear expectations, scoring system and rewards / coaching. Improve lean manufacturing.
- Reduce cost on several Raw Materials with transfer of material from totes / drums units to bulk tanks.
- Lead daily production meeting to discuss daily priorities in scheduling, shipping orders, maintenance work orders, head count needs, project improvement projects, safety issues and other hot topics.
- Lead project for Warehouse Inventory improvement and increase accuracy within 1% of cycle counts vs AS 400 systems by 70%.
- Complete cross training program within a year as per corporate requirements to achieve score card KPI goal.
- Reduced turnover in department below 5% from 15% in previous years. Achieve goal by increasing training and with the addition of incentive bonuses programs link with plant KPI’s.
- Champion on quality teams to evaluate Non-Conformances in order to implement Improvement Projects to increase quality, efficiency and cost reduction.
- Lead manager in EMS 14000 certification for Garland Plant.
- Internal Auditor for ISO 9001:2008.
- Increase efficiency by 10% in all manufacturing areas through improvements in area layout, automation implementation (mixers, PLC, conveyors, etc.), eliminate of waste in the process, area layout optimization and manpower max out utilization (training, cross training, and coaching).
- Train the trainer at management level.
- Aggregates, Concrete, Adhesive & Specialty Chemicals Manufacturer
Chemical & Production Plating Manager & Engineer
Eaton
Sarasota
08.2001 - 07.2012
- Perform different chemical testing in order to maintain the plating baths as per the required process specification.
- In Charge of the purchasing and inventory control of the Chemistry and Supplies for Plating.
- Realized different Design of Experiments to optimize the productivity and Quality of the process.
- Trained new operators on the different plating processes (Gold/Electro less Nickel, Copper, Tin and Cadmium).
- Successfully assist on the Area Cost Reduction Program.
- Realized several internal quality audits, including the ISO 14001 Standard.
- Aerospace Apache Helicopter Parts Manufacturer
Process Quality Engineer
Viasystems P.R.
San German
08.1997 - 07.2001
- Assist and support QS9000 Audit. Perform an Internal Audit in Preparation for the Annual Registration.
- Assist on Documentation & Process Review, FMEA, and PPIP & Validations.
- Realize Weekly/Monthly Quality Meetings for the analysis of the Manufacturing/Process performance. This includes a report with Pareto Charts (Top Detractors), Histograms, Frequency Charts, and other analysis sources. These meetings included people Action Plans for the main problems.
- Perform different projects for the improvements of the Quality and Optimum Capacity of Etching and Plating Process. These projects were done for the update of the machinery and a better product yield (Problem Solving & Trouble Shooting Techniques).
- Reduce chemistry and utilities cost 30% on the DES Line.
- Assist on the installation and validation of a new Oxide Process Line.
- Supervise two process lines with a total of 12 operators. Met productivity goals (On Time Delivery 90% and Cycle time 85%) and increase production up to 35%.
- Circuit Board manufacturer
Education
Bachelor of Science - Chemical Engineering, Chemistry and Mathematics
Universito of Puerto Rico
Mayaguez, PR05.1995
Skills
- SAP
- AS 400
- Razor
- Oracle
- Excel
- Power Point
- Word
- DOE
- Lean Manufacturing
- Six Sigma
Training
- Total Quality Management Training
- Six Sigma Yellow Belt
- SPC Implementation Program (QAS Software)
- ISO 9001 and ISO 14001 Exposure (3 years of direct participation with the internal auditor)
References
Available upon request
Timeline
Plant Manager
48Forty Solutions
05.2025 - Current
Plant / OPS Manager
Pedal Point Recycling
10.2023 - 03.2025
Plant Manager
Red River Brick
07.2021 - 10.2023
Operations Manager
Quikrete
04.2018 - 07.2021
Operations Manager
DAP Inc
09.2016 - 04.2018
Production Manager
Mapei
08.2012 - 08.2016
Chemical & Production Plating Manager & Engineer
Eaton
08.2001 - 07.2012
Process Quality Engineer
Viasystems P.R.
08.1997 - 07.2001
Bachelor of Science - Chemical Engineering, Chemistry and Mathematics
Universito of Puerto Rico