Ernesto Manuel Zavala Hernández

Ernesto Manuel Zavala Hernández Email and Phone Number

Production Manager - Plastics - KOSTAL Group
Ernesto Manuel Zavala Hernández's Location
Querétaro, Querétaro, Mexico, Mexico
Ernesto Manuel Zavala Hernández's Contact Details

Ernesto Manuel Zavala Hernández work email

Ernesto Manuel Zavala Hernández personal email

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About Ernesto Manuel Zavala Hernández

Operations Management in manufacture companies of plastic products for the auto-parts, pharmaceutical, food, bottling & beverages and health care, managing 4 plants and 650 employees, and reporting to CEO, COO and Shareholders. Responsible of products and projects, transferring and installing new facilities at local and international locations, being responsible of the operations management as well as team developer with operative areas involved such as planning, manufacture, maintenance, quality assurance, molds and tool shop, supply chain and engineering, and team builder with finance, sales and HR areas. Top level experienced in plastic processes. Graduated in Plastics.Capabilities• Molding Processes: Blow, Compression, Extrusion, Injection, Extrusion-Blow, Injection-Blow, Thermoformed, Subsequent Processes and Assembly of Automotive Components and Switches• BMS (Business Management System)o Visual Factory, Gemba, Balanced Scorecard, KPI's, VSM (Process Mapping), MPS (Manufacturing Process Systems), Strategic Planning • Lean Manufacture & Six Sigmao Kaizen, Poka-Yoke, SMED, 5S+1, TPS (Toyota Production System), TPM (Total Productive Maintenance), DOE, SPC (Statistical Process Control), Automation (Jidokas)• Quality Assurance & Supply Chaino TQM (Total Quality Management), ISO-9000, TS-16949, FSSC-22000, HACCP, GMP, PPM’s, FMEA, FIFO, DOH, Kanban, JIT, ABC Warehousing System• Financeo Financial Analysis and Income Statement (PBIT, P&L), Operations and Sales Budgets, Variations, Scrap and Waste Control, Costs Reduction, Headcount and Overhead• Core Competenceso Productive Processes Control (PPC), Decision Making, Leadership and Control Stress, Team Builder and Team Developer, Focused to Safety Plant, Accomplishment of Objectives and Goals with Defined Action Plans, Continuous Improvement in Processes, Control Costs and Budgets

Ernesto Manuel Zavala Hernández's Current Company Details

Production Manager - Plastics - KOSTAL Group
Ernesto Manuel Zavala Hernández Work Experience Details
  • Kostal Group
    Production Manager - Plastics
    Kostal Group Jun 2014 - Feb 2016
    Querétaro Area, Mexico
    Manufacture of mechatronic auto parts, electronic assemblies and plastic parts such as steering column and roof modules, remote control systems for doors, seats and windows switches, front panels, angle and rain sensors. SMT processes, multicolor plastic injection & assisted by gas. KOMEX is 3 plants in Mexico, 1800 workers, 30 assembly lines, 7 SMT, 90 injection molding machines with 2600 molds. Annual sales budget by $350MM USD and 185 million pieces of annual volume. Title: Production Manager - PlasticsReporting to: Operations Director (COO)Direct Reports: 5 persons in managerial levelResponsibilities• Operations management of the areas of injection molding, tool shop, maintenance, pad printing and service bureau contract manufacturers including development and control them with responsibility for quality product, production processes and maintenance of molds assigned to them• Strategic planning in the injection area and expansion projects focused on continuous improvement in profitability, sustainability, technology and business operationsAchievements• Increased 3% OEE level in the area of injection (81% to 84%)• Increased value added product from 3.4% to 4.2% (Added Value)• Improved results in KPI’s of Scrap, Corrective Actions (8D’s), Internal PPM’s, Lines Shutdown, Cavitation and establishing new KPI’s (MTBF MTTR) and usage of BSC and Dashboard for managing and visualization them• Surveillance Audit ISO/TS-16949 approved without comments and non-conformities in the same• Renewal of injection and pad printing machines based on investment plans and ROI justified• Shared responsibility for expansion & SOP of third plant project for injection molding and painting processes
  • Grupo Arcoiris Plasticos
    Operations Manager
    Grupo Arcoiris Plasticos Oct 2012 - Feb 2014
    Tlajomulco, Jalisco
    Manufacture of plastic containers for purified water (1 to 5 gallons), top caps, ophthalmic droppers and bottles (0.1 to 0.5 fl. oz.) for pharmaceutical and medical industries, producing inside cleanest rooms (10K, 100K and comfort classes). Molding Processes: Compression, Injection, Extrusion-Blow and Injection-Blow. Company Overview: 650 workers, 60 production lines, annual sales (mxn): $650MK, production volume: 813MK pcs/year. Title: Operations ManagerReporting to: President y Vice-PresidentDirect Reports: 7 persons in managerial levelResponsibilities• Direct the operation of the company coordinating the manufacturing area in conjunction with their service areas • Strategic planning in conjunction with the commercial and financial areas, aiming the profitability and sustainability of the company, with the proper allocation of resources, technology and project development • Continuous improvement of financial and operating results based on productivity, efficiency and decreased production costs and negative variationsAchievements• Increase the level of efficiency and productivity (OEE) from 76% to 81% • Decreased financial variations from 23% to 15% attributable to the operation of the plant • Cost reduction of scrap from $5.25MK to $3.16MK, meaning an improvement of 40% and placing the KPI to 1% • Operating income of 7% real, against 9% projected with downward deviation of sales from 11% of Budget • Savings of $650K for restructuring areas and reducing differences in inventories from $700K to $113K • Certification of the plant: FSSC 22000:2010 and recertification ISO-9000:2008
  • Industria Mexicana De Plásticos Olimpia Sa De Cv
    General Manager
    Industria Mexicana De Plásticos Olimpia Sa De Cv Jan 2012 - May 2012
    Los Reyes Acaquilpan, México
    Plastic containers and top caps manufacturer by injection molding process, extrusion-blow and injection-blow for several industries, with budgeted annual sales of $10MDD. The company operates with 350 workers, 30 production lines and 13 machines for silk screen process.Title: General ManagerReporting to: CEO and 2 Corporate Presidents Direct Reports: 7 persons in managerial levelResponsibilities• Management of the company with measurement in operational, financial, administrative and commercial areas• Strategic planning in the areas of trade and finance, allocating resources for the operational area, looking for profitability and bailout of the company• Increased share trading in the active market, development of projects and new clientsAchievements• Implementation of Balanced Scorecard, measurement and establishment of KPI's• Reach the point of balance of the company with the increase in sales ($7.5MDD), and projecting positive trend for the next few months ($8.5MDD)• 30% increase in participation on the actual market and getting projects for developing new products• Approve audit of surveillance ISO9000:2008 and establishment of actions to approve HACCP audit
  • Amcor Rigid Plastics
    Regional Operations Manager
    Amcor Rigid Plastics Jul 2009 - Jan 2011
    Zona Noroeste (Hermosillo - Chihuahua - Cd. Juárez)
    Blow molding of PET containers and injection molding of preforms for bottling and beverages industries. Annual sales budget of more than $100MDD in Mexico. The company operated 12 plants in the country and more than 1000 employees in the organization. The company's infrastructure was 25 injection molding machines and 30 blow molding lines including labeling machines and palletizers.Title: Regional Operations ManagerReporting to: COODirect Reports: 25 persons in managerial positions such as plant managers and department managers.Responsibilities • Management of the operation of three plants located in the Northwest (Hermosillo, Chihuahua, Cd. Juarez)• Responsible for the financial and operations results of the zone and of every manufacturing site• Control and projection of budgets and investments (CAPEX) for the Northwest region by assigning resources to each of the plants according to the execution priorities for implementation, projects and needs• Maintain the conditions of security of the plants and quality systems assurance• Relationship direct and continuous with the customer to control supplies and projects• Strategic planning focused on continuous improvement and costs reduction Achievements•92% of the PBIT of the region ($6.1MDD) and 95% of sales budget ($32MDD)• Reduction of 7% of expenditure in accordance with the established budget•$ 400 K dollars saved in raw material by the use of recycled material and settings in usage variance•Approval of quality assurance systems (HACCP, GMP, QSE)•Presidential Safety Award obtained at each of the plants under my responsibility•Production record volume of 800 million of preforms and 450 million bottles in the region
  • Aceros Camesa (A Wrca Company)
    Plant Manager - Electromechanical Cable Division
    Aceros Camesa (A Wrca Company) Dec 2008 - Mar 2009
    México, D.F.
    Manufacture company of wire, strands, wire rope, optical fiber and electromechanical cable products for oil field, construction, mining, fishing, telecommunications, automotive, etc. by strand and plastic extrusion and co-extrusion processes. Main customers: Halliburton, CFE, PEMEX, Michelin. Company has more than 1000 employees in Mexico.Plant Manager – Electromechanical Cable Division• Coordination and of the activities for the engineering, financial, production, quality control and maintenance areas, establishing metrics systems and KPI´s for measurement of the performance of each different area by Visual Factory• Improvement of the extrusion process capacity and capability for polymers of engineering (example: PTFE-Teflon) due to my technical assistance, and as consequence, an improvement in the productive and financial results of my area of responsibility• I managed 120 workers and reporting to national and international COOReason for leaving: Worldwide Economic Status affected prices for barrel of crude oil.
  • Schlemmer Sa De Cv
    Plant Manager
    Schlemmer Sa De Cv Oct 1998 - Sep 2008
    Puebla De Zaragoza Area, Mexico
    Manufacture of cables protection systems and air & fluid conduction systems for automotive & electrical harnesses industries. Tier1&2 supplier. Plastic processes of extrusion, thermoforming and injection molding, assembly of auto-parts. Annual sales of $10MDD, $1.5MDD of PBIT. Company employees 120 peopleTitles: Plant Manager, Operations & Production ManagerReporting to: CEODirect reports: 6 persons in managerial position and 4 people in operating levelResponsibilities• Management of the company, responsible for operational, financial and commercial areas in Mexico and technical assistance for the operations of the Brazilian plant• Project management for new products, processes and customers, with responsibility in the NAFTA region• Installation and start-up of the plants of Mexico and Brazil with the approval of initial samples and trainingpersonnel (plant manager, production manager, maintenance manager, supervisors and operators)• Certification of the company in quality systems assurance: ISO9000, TS16949, QS9000 VDA6• Strategic planning of the company to increase profitability and improvement in production processesAchievements• 86% of the PBIT and 79% of the sales budget in times of crisis for the automotive industry• Closure of projects with BMW and Honda generating transfer of technology and new processes in Mexico• Accredited certifications in TS16949, QS9000, ISO9000 and VDA6 and surveillance audits• Opening business in the automotive industry as TIER2 for VWM, Nissan, GM, Ford, BMW and Honda• 19% increase in sales on the basis of strategic planning, technical assistance and negotiations in the USA• 7% reduction of operating costs and inventory levels• Responsible for the project of installation, start-up and approval of plants located in Mexico and Brazil.• Maintain operations at levels higher than 97% of efficiency and less than 3% of WIP and Scrap• Development of raw material suppliers to consumer products in the NAFTA region
  • Inplax, Sa De Cv
    Plant And Operations Manager
    Inplax, Sa De Cv Oct 1982 - Sep 1998
    México, D.F.
    Plastic containers and top caps manufacturer, supplying industries such as nutritional, pharmaceutical, cosmetic, food, liquor, packaging, personal care, and home care. Plastic processes: injection molding and extrusion-blow. Infrastructure of 40 injection molding machines and 6 extrusion-blow molding lines, employing 250 workers in operations, printing, silk screening and assembly areas, managing an annual budget of $10MDD sales.Titles: Plant Manager, Production and Maintenance ManagerReporting to: General Manager, Partners and ShareholdersDirect reports: 5 persons at managerial level and 6 people in operating levelResponsibilities• Administration of 2 plants with responsibility for the financial and operations results• Production planning and establishment of indicators of measurement for all areas• Development and care of clients and external manufacturers (maquila)• Management of improvement projects in machinery and installations• Implementing work methodologies based on quality circles and team workAchievements• Increase the level of customer service from 47% to 70 %• 21% increase in sales and billing• Increase of operations efficiency from 65% to 83 %• Decrease WIP and Scrap from 11% to 3 %• Saving costs of 3% in use of electric power and 8% in raw material usage• Increase of machinery reliability from 65% to 90% by improving the quality of maintenance• 18% personnel downsizing because efficiency in operations, automation and maintenance of molds• Project management of expansion of electrical substations and cooling systems

Ernesto Manuel Zavala Hernández Skills

Lean Manufacturing Six Sigma Business Development Value Stream Mapping Gemba Kaizen Leadership Balanced Scorecard Plastics Industry Automotive Statistical Tools Process Control Quality Assurance Ts16949 Lead Management Team Leadership Customer Service Financial Analysis Product Management Production Managment Manufacturing Operations Management Business Management Executive Coaching Strategic Operations Planning Tpm Team Building Proactive Self Starter

Ernesto Manuel Zavala Hernández Education Details

Frequently Asked Questions about Ernesto Manuel Zavala Hernández

What is Ernesto Manuel Zavala Hernández's role at the current company?

Ernesto Manuel Zavala Hernández's current role is Production Manager - Plastics - KOSTAL Group.

What is Ernesto Manuel Zavala Hernández's email address?

Ernesto Manuel Zavala Hernández's email address is er****@****msn.com

What schools did Ernesto Manuel Zavala Hernández attend?

Ernesto Manuel Zavala Hernández attended Instituto Politécnico Nacional.

What skills is Ernesto Manuel Zavala Hernández known for?

Ernesto Manuel Zavala Hernández has skills like Lean Manufacturing, Six Sigma, Business Development, Value Stream Mapping, Gemba, Kaizen Leadership, Balanced Scorecard, Plastics Industry, Automotive, Statistical Tools, Process Control, Quality Assurance.

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