Javier Manzo

A strategist and honest executive with 22 years of manufacturing experience with extensive track record in all areas of the maquiladora environment, starting as a Line Lead developing into a Site Director, Leading, and Transforming organizations at maximum Efficiency and Productivity by the most effective use of six sigma and lean manufacturing tools, Always focus on Safety & continues improvement as way of live.

PROFESSIONAL HISTORY

 TBCYM                         BUM Tijuana México                                                                 Nov 2017 – Actual

In charge of a manufacturing, Sales and customer care facility, with 880 DL and 170 IDL.

Reporting directly to GM and working on a daily basis with the CFO to ensure financial positive records.

Managing: EHS, Operations, Finance, Human Resources, Quality, Engineering, Facilities, Supply Chain, 

Implementation of Mission, Vision and KPI’s for all on-site departments with a focus on continuous improvement 

Responsible for devising and controlling the annual operations budget and PNL.

Responsible for reviewing all P.R. And approve P.O. BY  5K on SAP following variances reports and needs.

Assure all P.O. It can be produced and shipped from our clients with quality, on time delivery and good cost. 

Presents to the Corp. on the management review meeting the results of the company and new projects with ROI. 

Coaching my staff members working with HR programs and leading by example. 

Keep track of the new machinery and technological systems to drive the company to the next level quarter. 

Ensure that the manufacturing process works in accordance with GMP’s. 

Budget and Resources Management assuring a P&L positive record. 

Date to Date meetings with clients to ensure good costumers’ satisfaction and work on sales increase with new clients, by offering our services based on our strongest costumer services and our good achievements in terms of quality, delivery cost, NPI and continues improvements. 

Main Achievements:

• Increase sales by 42% 15 MDD FY 2022 by NPI Projects, Increasing production floor utilization on 39 %. 
• Implement the Employee Excellence Program, this is all about Communication, Recognition, Carrier Development. and Performance Management. Reduction Of turn Over from 12% to 2%
•  Implementation and tracking day by day the escalation process, productivity increase by 13%.
•  On time delivery improved from 65% to 98%. With the implementation of lean production planning systems.
• Maintain all STPS Studies and Government permits up to Date year by year to avoid any fee to the company.
•  Leader on the Implementation of SAP System in all departments.
•  Responsible for the program application of C-TPAT having a success with the application. 
• Warehouse optimization by 47% by doing re layout, Inventories, and cycle counts plus working with suppliers on lead times and the quality of the raw materials. 
• Introduce 22 new products in FY 22 IQ, OQ, PQ ramp up and mass production all on time and on budget.  
• Implementation of Lean and six sigma philosophy on the company $545k on savings by reducing, Time, Defects, Scrap, Headcount and Overhead.   

   Flex                              Sr. OPS. Manager, Tijuana, México.                                             Nov 2013 – Nov 2017

In charge of 3 clean rooms. 2 Class 7 and 1 Class 6, with 749 DL and 65 IDL Reporting to Sr. Dir. Of Ops. 

Reporting directly to me 2 Ops Managers,1 NPI Manager and 17 supervisors on charge.

Leading the GEMBA meetings daily, reviewing all shifts results and giving support in all aspects of the process.

Responsible that all trainings records of my team be up to date according to regulatory program. 

Responsible for controlling and approving the payroll and promotions of all my directs repots.  

Coordinate the CFT meetings to review the opportunities to provide extraordinary costumer service to our clients.

Assure that all production lines achieve or exceed the product rate with good Quality, Delivery, and cost. 

Work with the CFT and Clients on the NPI process by making sure that we have smooth NPI process. 

Main Achievements:

• 11 Successful Plant Transfers from la Mesa Industrial Park to Otay Industrial Park (Buffer Build, Validations, IQ, OQ, PQ, Trainings, and line rump up with zero impact to organizations KPI’s. $7.5 MDD On Savings.
• Reduction of personnel turn over from 11% to 1.8% working with HR and Engineering departments by designing ergonomics stations and best place to work program.
• Increase sales from $60 MD to $85 MD by quarter on FY 18 by Improving NPI Process, Plus the implementation of QBR Meetings Face to Face whit the customer to achieve quality, delivery, and cost benefits.
• CAPA implementations reducing weekly quality product findings from 14% to 1.3%.
• Hours per Unit Improvement 10% 2015 and 15% in 2016.
• $475k USD Hard Savings through Scrap reduction.
• Improvement of Molding cycle time Process ($248k on Hard Savings).
• FDA Audit management – 6 audits – 0 findings.

    PDC                            Plant Manager Tijuana, México.                                                             Jul 2007 – Nov 2013   

Managing: Production, Human Resources, Quality Assurance, Finance, Maintenance, Engineering, Supply Chain, Import-Export, Production Control and OPEX Managers.

                                                      Reporting Directly to VP of Operations and presents monthly KPI and financial metrics to board of directors.

Management for Mexico operations (1050 direct/150 indirect employees, 2 Buildings 196, k SF. & 120 K SF.

                                                      Ensure that all the production orders are produced up to schedule with QA, delivery, and Cost.

                                                      lead day to day the operations staff meeting and monthly meetings with all employees and Corp. meetings.

Responsible to develop and control budget and P&L, of the entire organization (headcount/overhead/materials)

Responsible for all plant strategies and activities related to customer care, customer services and sales increase.

Lead the safety committee of the entire organization to be sure that the company is a safe place to work and be in compliance with all STPS studies and government permits.

        Main Achievements:

• Successful Operation transfers (transferring of 5 complete manufacturing facilities from Belgium, Texas, Chicago, Florida, San Fernando & 10 Flexographic press machines Transfer from China. 12.5 MD Savings.
• Opening of a second manufacturing plant starting from construction all the way to production.
• Implementation of 6 “S” and Lean Programs in USA, Mexico & Belgium Europe Facilities (5) 
• $10,500,000 savings with Lean Manufacturing and Kaizen activities (HC, OH, MAT) 
• Managing Growth from $7.5 MD to $101 MD On sales & from 110 Employee to 1200 Employee
• Inventory turns increase from 4 to 12 Inventory turns per year.
• Training, develop and promotion seven supervisors to a manager position on a period of 3 years.
• $800k saving by transferring shelter operations (Human Resources, Finance/Accounting, import-export, safety

and environmental).

• Cero accidents during a period of 2 years and 8 months.

Black & Decker            Engineering/Maintenance Manager       Mexicali, Mexico.        June 2004 – July 2007

Managing: 4 Supervisors, 7 Engineers, 25 Maintenance technicians, 2 assistant                                                     Process control program at final assembly (Operation Sheets, Visual Aids, First Article Format, Products Specs, In process Audits, Time Studies, Ergonomic Stations, Safety, Poka-yoke, Tooling, Fixtures.

Monthly resources calculation based on market demand. 

Administration of Plant Layout, Facility maintenance program and new products introduction programs.

TPM Preventing and corrective program implementations

        Main Achievements:

• Machinery and Equipment transfer Project from Texas to Mexicali $639 K on Impact.
• Implementation of Kaizen Activities Program (Upgrade, Rebuild Machinery) $271 Cost Reduction
• One piece flow project implementation, $3.5 MD Savings. 
• Spare parts inventory control programs cost savings impact of $102 k.
• Implement Monthly Audits to verify the efficiency of the inventory control system.
• Maintenance Work Orders Program Implementation, Equipment Down Time Reduce 65%.

SONY                            Production and Engineer Supervisor,    Mexicali, Mexico.                     Nov 1999 – June 2004                     

Objective: Exceeded plant FY targets (Space optimization/Head count reduction/Scrap ratio/Inventory turns/ Quality Metrics/Downtime machine/Cost per unit savings and out puts targets.

Production lines coordination. (90 People 3 Jr engineers and 2 production Leaders on Charge).

Coordinate Staff Kaizen activities (Participating President, VP, Japanese Staff, and Managers), Lead weekly and monthly and activities. (Waste elimination/Cost reduction programs).

Lean Manufacturing and Kaizen Trainer. 

Implement Value Stream mapping for all sites departments.

                                                      Kaizen database management and budget control.

                                                      Calculate resources needed for each line based on demand.

                                                       Main Achievements:

• Innovation projects administrator. (Implement SMT project & One Building Project) 2.5 MD on savings. 
• Scrap reduction from 0.45% to 0.10% ($37K monthly savings). 
• Cell process design & implementation. Production on product mix increased by 45%.
• Plant layout administration 25% of free space for NPI.
• HC Calculation Responsible reducing 15 % by applying lean manufacturing and 5 S activities.
• Material flow designed reducing material shortages to 0 % by application of KANBAN and JIT.
• New Product Introductions responsible 7 NPI OQ, IQ, PQ, pre-production, and mass production.
• Process control management achieved 6 sigma during a period of 8 months.

EDUCATION

 Industrial Engineer.              Universidad Autónoma de Baja California                       Mexicali, México 

 MBA                                                 CETYS                                                                                                     Tijuana,  México 

                         Certifications                                                                               Date                     Awards                 Company

• Six Sigma Black Belt Certification By IDET                                         Feb.   2010         Best Production Supervisor      SONY
• Lean Manufacturing Certification for Managers.                                   Jul.     2013        Best Six Sigma project         Black/Decker
• Statistical Process Improvement Certification.                                       May.  2005        OPEX Quality                      Black/Decker
• Finances & Variances Control Training CETIS.                                    Jul.     2018       Best Plant Manager                   pdc
• Alta dirección empresarial Certification.                                               Sep.    2015        Best Plant Manager                  pdc
• Taller De Liderazgo CETYS.                                                                  Jul.    2007        OPEX Productivity                  pdc
• Kaizen Champion Training                                                                    Feb.    2004        SHAREHOLDER                    pdc
• Reformas Fiscales by BDO                                                                    Mar   2013         Best Sr Ops Manager              FLEX   
• APQP control Plan                                                                                Oct.     2020         Best Lean Project                    FLEX                                                   
• Training, Optimización de Habilidades de Calidad By Evolución        Jan.     2021       Team Building                     TBCYM
• APICS Training (Inventory Record Accuracy).                                    Mar.   2022         Lean Implementation          TBCYM

EDUCATION

 Industrial Engineer.              Universidad Autónoma de Baja California                       Mexicali, México 

 MBA                                                 CETYS                                                                                                     Tijuana,  México 

                         Certifications                                                                               Date                     Awards                 Company

• Six Sigma Black Belt Certification By IDET                                         Feb.   2010         Best Production Supervisor      SONY
• Lean Manufacturing Certification for Managers.                                   Jul.     2013        Best Six Sigma project         Black/Decker
• Statistical Process Improvement Certification.                                       May.  2005        OPEX Quality                      Black/Decker
• Finances & Variances Control Training CETIS.                                    Jul.     2018       Best Plant Manager                   pdc
• Alta dirección empresarial Certification.                                               Sep.    2015        Best Plant Manager                  pdc
• Taller De Liderazgo CETYS.                                                                  Jul.    2007        OPEX Productivity                  pdc
• Kaizen Champion Training                                                                    Feb.    2004        SHAREHOLDER                    pdc
• Reformas Fiscales by BDO                                                                    Mar   2013         Best Sr Ops Manager              FLEX   
• APQP control Plan                                                                                Oct.     2020         Best Lean Project                    FLEX                                                   
• Training, Optimización de Habilidades de Calidad By Evolución        Jan.     2021       Team Building                     TBCYM
• APICS Training (Inventory Record Accuracy).                                    Mar.   2022         Lean Implementation          TBCYM