Robert Castillo Email & Phone Number

Saint Johns, Fl, Us

St Augustine, Florida, United States

Daytona Beach, Florida

Led a team of 8 Project Managers responsible for the on-time execution and delivery of over $60M, 24 major projects, delivering thousands of products to domestic and international customers.• Responsible for developing goals and objectives for the team.• Actively reviewed team’s performance (including mine), encouraged best practices and highlighted opportunities for improvements. Advised, coached, and mentored team members on projects as well as career growth.• Encouraged professionalism, listening, respect, safety culture, and motivated the team to focus on company’s goals and objectives.• Assisted team with projects in emergencies or short term resource constraints.• Developed improved performance metrics to review projects performance and improve accountability.• Worked with other group leaders to review the entire execution process, identify systematic inefficiencies, and develop an improvement plan to address findings.• Coordinated with Engineering leadership to implement a plan to improve the lead time for drawings prioritization, customer approval, and release to operations.• Responsible for developing improved performance metrics and reporting formats. • Developed automated projects performance Dashboards using MRP data and Business Intelligence tools.• Responsible for presenting monthly project status updates to company’s President and upper management.• Justified additional support requests to upper management to mitigate late delivery risks.• Responsible for end of the year performance reviews, merit increases, and help map individuals future career goals.• Held biweekly team meetings to discuss project status, issues and successes, and possibilities for improvement.• Responsible for hiring, approving expenses reports, vacation, and ensuring training matrix for each team member is in compliance.

Daytona Beach, Florida

Responsible for reviewing project’s scope of work, planning and executing product development project according to a phased based product development process which enables a robust manufacturable design, high product reliability, meets first pass yield requirements, and exceeds customers’s specifications.Managed all critical deliverables, from proposal, specifications, engineering, material procurement, prototype build and testing/certification, customer reviews and approval, document release, planning, manufacturing, QA and shipment.Defined project scope, goals and deliverables to support milestone goals in collaboration with engineering, drafting, purchasing, build/testing Technicians, manufacturing introduction, and operations teams.Developed full-scale project plans and associated communications documents.Responsible holding projects Kickoff meeting with cross-functional stakeholders.Managed all internal and external interfaces during project execution.Negotiated with other department managers for the acquisition of required personnel from within the company to mitigate resource constraints.Identified and resolved issues and conflicts within the project team.Identified and managed project’s critical path and dependencies.Conducted project lessons learned and create a recommendations report in order to identify successful and unsuccessful project elements.Coordinated client visits, project and approval reviews.

Daytona Beach, Florida Area

Responsible for planning, executing, and finalizing production projects according to customer’s specifications, deadlines, and within budget.Managed all critical deliverables from pre-order scheduling, order entry, engineering design, document release, planning, manufacturing, QA and shipment.Defined project scope, goals and deliverables to support milestone goals in collaboration with project execution and operations teams.Responsible holding projects Kickoff meeting with cross-functional stakeholders.Developed full-scale project plans and associated communications documents.Developed initial schedule for new products while in the pre-order state.Developed schedule in support of engineering and production promise dates at order entry and through design and build cycle.Managed all internal and external interfaces during project execution.Negotiated with other department managers for the acquisition of required personnel from within the company to mitigate resource constraintsIdentified and resolved issues and conflicts within the project team.Identified and managed project’s critical path and dependencies.Planned and scheduled project timelines and milestones using most appropriate tool.Determined the frequency and content of status reports from the project team, analyze results, and troubleshoot problem areas.Conducted project lessons learned and create a recommendations report in order to identify successful and unsuccessful project elements.Communicated all issues across organizational boundaries with Sales Management to assure client satisfaction.Coordinated client visits, project reviews, and satisfaction improvement efforts.

Led the development and manufacturing transition of a complex Electro-Optical-mechanical system. Managed activities for Design Engineering, Manufacturing Engineering, Test, Reliability, Service, Production, and Quality groups.Managed a cross-functional DFX project with the goal of improving the manufacturability and reliability of the product. DFX design changes resulted in a 85% increase improvement in production throughput and 58% in product reliability.Coordinated DFMEA and PFMEA on subassemblies and production processes to better optimize the product design and its manufacturability.Managed a $500K Capital Budget for Manufacturing Engineering.Successfully managed the production and on-time delivery of $2.6M in customer orders of early development product.Reported Product Development progress, risk assessment, and mitigation’s to cross-functional teams including CTO on a regular basis.Coordinated Pilot and Qualification builds for New Products, both in house and with Contract Manufacturers.Managed material and inventory for early phases of the project and worked closely buyers and planning to properly transfer these into production environment of the MRP system.Provided leadership in data driven, root cause analysis to resolve technical problems and continuously improve the existing production methods to remove waste, mistake proof and optimize the process.Managed the Design and acquisition of production tooling and test equipment from contractors.Managed and mentored multiple Manufacturing Engineers (indirects).Provided product costing models and labor estimates and validated/adjusted them in actual prototype builds.Created Visual Work Instructions and conducted process training for all new assembly builds.Performed process failure mode analysis and implemented corrective actions on all pilot builds.Worked in a class 10,000 clean room (some projects)

Planned and coordinated Prototype & Pilot product builds of the new industrial laser products which lead to the successful launch to evaluate the design and processes in preparation of full scale production release.Supported the development organization by leading the manufacturing effort to define and drive design for manufacturing with the goal of reducing assembly and test time, and increasing the overall product reliability.Responsible for providing design for manufacturing feedback as well as root cause analysis reports to the R&D development team which resulted in a more reliable and easier to manufacture product.Responsible for setting up production stations and process flow for the new product.Responsible for developing and designing new tooling, fixtures, assembly drawing and methods.Worked closely with quality and manufacturing department to develop, coordinate, and implement technical training for employees.Responsible for making "make" vs. "buy" analysis and decision for assemblies.Perform Yield and CPK analysis for critical processes.Effective in determining root cause and corrective actions on startup production issues.Created Process Flows, Value Stream Map (VSM) and PFMEA for new and existing products.Optimized manufacturing floor layouts including clean room areasResponsible for creating product structures, process flows, product routings, BOM, ECOs, and initial product setup in PLM & MRP systems.Worked in class 10,000 clean room (75% of the time)

Responsible for developing a project plans and delivery schedules of engineering turn-key solutions to our customers for R&D, NPI, System Integration, and Manufacturing applications.Account manager and main point of contact for our customer in multiple facilities.Responsible for driving and understanding customer's requirements.Responsible for developing and presenting concepts to the customer.Responsible for identifying process inefficiencies in current manufacturing processes to drive new business by offering innovative engineering solutions to our customer.Designed fixtures to improve manufacturability of products and reduce setup time for customer's processes.

Worked concurrently with R&D, organizations and vendors through all phases of the product cycle to ensure a successful on time release of new products. Implemented lean manufacturingmethodologies and processes for new products.Planned and coordinated model builds and manufacturing transition of the new products to the production floor. Provided model evaluation and design for manufacturing input to R&DWorked with subcontractors to assess capabilities, reviewed process plans and controls, drove continuous improvements, and resolved production issues on the floor.Performed source inspection at contract manufactures and generated feedback reports and tracked any action items.Created and maintained assembly instructions for the manufacturing of production products and provided training on procedures and assembly methods for various product lines.Worked with supply chain to ensure that material was properly set up in our systems and available on time.Created an outsourcing plan to enable Lucent to increase build capacity, have a more robust supply chain, and to reduce production costs for various product lines.Developed capacity planning tools to enable management run different capacity scenarios and give our sales and marketing teams more accurate production capabilities, and production volumes acceptance levels.Analyzed internal capacity to help determine what product to outsource and provide suggestions for capital allocation to upper management on a regular basis.Worked closely with Production Managers, Test, Product, Process Engineers to fully understand current and future plant capacity requirements for each product to determine outsourcing strategies.

Quality/Process Engineering Consultant to new manufacturing suppliers. Responsible for auditing the overall production quality of new vendors, compliance with ISO9002 & 14001, and incoming qualities from vendors for print cartridges and toner dispensers.Analyzed current product's design in an effort to explore different materials and manufacturing techniques that help in reducing the overall cost of the product. Designed fixtures to stream line the cycle time and foolproof current processes.Created and maintained assembly instructions for the manufacturing of production products and provided training on procedures and assembly methods for toner dispensers.Responsible for rebalancing and troubleshooting the production lines to adjust for changes in production volume schedules.