Rogerio Carvalho Email and Phone Number
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Rogerio Carvalho personal email
I am graduated in Industrial Engineering and Metallurgy with MBA courses in Business Management by FGV. Fluent Italian and English.25 years experience in the automotive , Oil & Gas and steel industry, with International experience direct action in the areas of Continuous Improvement, Process Engineering, Product, Manufacturing and Quality. Exercising diversified activities, but focused on the development and planning processes and products.Refresher courses: 6 Sigma Black Belt and Advanced Statistics, Manufacturing Excellence-USA, Value Stream Mapping, DOE, Lean Manufacturing (Kanban, Set-up fast, KAIZEN), ISO9000, ISO14000, QS9000, TS16949 certification.Specialties: Product and Process Development,Black Belt in 6Sigma,Process Approach Development,New Product Management,Lean Manufacturing Tools Implementation,Production and Process Improvement,Emphasizing cost reduction,Managing people, teamwork.
Corbion
View- Website:
- corbion.com
- Employees:
- 1683
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Ci ManagerCorbion Aug 2020 - PresentCampos Dos Goytacazes, Brazil-To actively monitor risks to foresee/identify potential problems and proactively identify solutions to address in advance-Identify trends and process variations as part of establishing a continuous improvement monitoring system, establishing and maintaining plant KPI’s and visual factory tools.-Offer technical expertise to company on statistics, Quality Tools, Six Sigma methodology, tools and practices.-Support the delivery of better value and greater efficiency through the identification and elimination of unnecessary complexity within business processes, identification of better ways of working and elimination of wastes.-Deploying and coaching CI tools Contribute to the development and implementation of CCP Initiative on Continuous Improvement across all levels of the organization to deliver business results.-Manage continuous improvement projects as well as monitor and coach improvement project teams, with results mindset.-Leading the plant wide cost savings program to meet annual targets. This includes identification, validation, coaching and execution of projects (in terms of timelines, budget and resources). -
Process Improvement EngineerTrelleborg Offshore Dec 2016 - Aug 2020Macaé Area, Brazil- Supporting the Operations Manager by providing technical expertise, developing, improving and maintaining systems, processes, procedures and process controls by utilizing expert skills acquired in composite/polymers, engineering problem solving and six sigma/lean methodologies at extrusion and molding process;- Application of techniques (i.e. SMS; etc.) to improve manufacturing and administrative processes (i.e. throughput, equipment reliability, product quality, and etc.);- Analysis of operational data, process maps, etc. to identify improvement opportunities;- Develop solution proposals including baselines, project timelines, resources requirements, progress tracking /sustaining, etc. to realize benefits;- Facilitation of continuous improvement activities and development of key internal Champions to drive future activities;- Investigation and transfer of best practices and process improvements to divisions globally;- Product raw material calculations.- Apply statistical methods to estimate future manufacturing requirements and potential;- Develop and evaluate equipment and process to produce a high quality product at a competitive cost;- Participate in qualification/development of suppliers for components, sub-assemblies and processes;- Facilitate development of corrective actions to resolve manufacturing issues;- Establish and document manufacturing processes;- Conduct manufacturing feasibility review; generate assembly instructions and tooling;- Provide technical direction, training and certification for operators performing detail process steps to ensure that the team have necessary skills, appropriate documentation, tooling and process control capability;- Resolve technical problems which effect quality, delivery and costs;- Manage the specification, sourcing and installation of new equipment through to manufacturing;- Ensure strict compliance with all Standard Operating Procedures with particular reference to health, safety and quality. -
Advanced Process Engineering ManagerCooper Standard Aug 2014 - Sep 2015Varginha Area, Brazil- Managed Engineering duties at Extrusion operations EPDM and Thermoplastic TPO/TPE, as well as Die shop-Tooling Manufacturing and Material Development.- Managed all process development and modifications to PSA, Honda, Toyota projects, prototyping, manufacturing and monitoring machines, following the assembly of parts for validation of processes and products as TS16949 standards, procedures and requirements of the customer until ramp up phase. - Provided Engineering support to new product team to ensure that all products introduced into manufacturing meet product and process quality criteria defined by customers. - Checked schedule applying MS Project, phases of the project, taking actions to ensure the deadlines agreed with the client. - Established the design review and project review to meet the goals of implementation of new programs and processes. Promote audits and meetings of decision-making of the Project. - Managed and ensured the deployment of new tools for continuous improvement (VSM, KAIZEN, SPC, TPM, SMED, 5S).-Defined specifications, selected suppliers and supervision the timely implementation of process, tooling and equipment according customer expectations.- Developed, implemented and maintained an aggressive focused approach to product testing and process/product, quality measurement.- Coaching the team on problem solving applying PDCA, Minitab and 6Sigma tools for all process to find RCCA to reduce downtime and scrap.- Supported QSB with participation on Fast Response, 8D report, PFMEA, Poka-Yoke, Lessons Learned, Standard Job and Audits.- Quality System member reviewing and updating the procedures of Process. - Ensured safety of personal, goods and compliance to CSA environmental policies.- Participated on weekly base of Technical Worldwide Conference about Process standardization.- Technically supported the commercial team during RFQ and CAPEX assessment.- Drove performance improvement and tooling maintenance on Die Shop area. -
Industrialization And Process Engineering ManagerHutchinson Automotive China Jul 2012 - Jun 2014Wuhan - China.- Managed Manufacturing Engineering duties at Extrusion Lines (EPDM and Thermoplastic TPO/TPE ) and Finishing operations (Cutting, Molding, Assembly, Gluing, Printing, Packaging), as well as Tooling Manufacturing and Materials Development. - Coordinated in terms of cost, quality and timing, the production launch of new projects, as well as production transfer projects, according internal and external customers procedures. Projects developed: Ford (C520, CD391), Volvo (L421), JLR (L538) using pull system concept. Since the flowchart definition, Equipment’s definition, Lay out, Control Plan, Work Instructions, industrialization phase and ramp up for SOP.- Selected, validated and coordinated the implementation of optimized material specifications.- Coached the team directly and indirectly on problem solving applying Minitab and Six Sigma tools for extrusion and finishing process to proceed troubleshooting and route cause analysis.- Worked with the Purchasing Team on supplier development activities for new programs.- Elaborated and control the CAPEX and cost accounting.- Managed spending against budget, control spending in relation to manufacturing.- Trained/developed local team and specifically supervision and management to support transition of responsibilities to the local team.- Drove OEE improvements at extrusion and finishing process.- Actively participated on elaboration and implementation of quality problem solving activities;- Guided Associates in the implementation of continuous improvement for process and product.
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Manufacturing Engineering & Continuous Improvement ManagerCooper-Standard Automotive South Korea Mar 2011 - May 2012Seocheon-Gun, Chungcheongnam-Do, Korea- Managed Manufacturing Engineering duties at Extrusion Lines (EPDM, Thermoplastic TPO/TPE ) and Finishing operations (Cutting, Molding, Assembly, Gluing, Printing), as well as Tooling Manufacturing and Materials Development. - Provided Engineering support to new product to ensure that all products introduced into manufacturing meet product and process quality criteria defined by customers and plant goals. - Ensured the smooth running of existing projects as well as flawless launches of new products (new and eventual inter sites product transfers) according to CSA and customer procedures.- Looked for continuously optimizing the overall performance – reduction of cost and maximization of profit using DMAIC (6Sigma).- Actively participated on elaboration and implementation of quality problem solving activities;- Provided the training and coached to team members.
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Extrusion Lead Process EngineerCooper Standard Automotive South Korea Jul 2010 - Feb 2011Seocheon-Gun, Chungcheongnam-Do, KoreaObjectives and responsabilities:A) Overall Output and efficiency extrusioni) Extrusion line speed improvementii) Scrap reductioniii) Labor efficiencyiv) Set up best practices B) Flawless launch of new projects (profiles) on extrusionC) Assist on maintenance plans and execution on extrusion D) Support Planning team towards maintenance of reduced inventory levels; develop lean initiativesE) Coach the team directly and indirectly on problem solving related to extrusionF) Train/develop local team and specifically supervision and management to support transition of responsibilities to the local teamG) Technically support the commercial team during business quotation and capital expenditure assessment, and teach these skills to the local team.
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Program ManagerCooper-Standard Automotive Mar 2005 - Jun 2010Brazil- Managed all new product development and modifications for Fiat, Iveco, MBB and Pilkington, operating from Co-design project, prototyping, manufacturing and monitoring machines, following the assembly of parts for processes and products validation with prototype and final tooling as TS16949 standards, procedures and requirements of the customer. - Check schedule with MS Project, taking actions to ensure the deadlines agreed with the client. - Establish the interface between the sectors, meetings of advancement of the project, to meet the goals of implementation of new programs and processes. Promote the interface between customer and internal sectors of audits and meetings of decision-making of the project, promoting the necessary negotiations. Report the project status to management based on cost, quality and timing.- I received the prize" Fiat Qualitas-2006 "for outstanding product development among suppliers to Fiat Punto platform. - Advise management guidelines using Lean 6Sigma tools to develop new products, seeking opportunities to reduce cost and increase profit margin. (Gap Analysis). - Responsible for technical analysis of RFQ to interface with Engineering and Industrial Sales. - Responsible for the development of the entire production process, machinery, tools, sizing of manpower, and analysis of time in the extrusion lines for new projects. - Elaborate process flow and management of DFMEA / PFMEA. -
Process EngineerCooper-Standard Automotive Jun 1999 - Feb 2005BrazilResponsible for the development of the entire production process, machinery, tools, sizing of manpower, analysis of time in the extrusion lines and production cells for new projects. . Elaboration process flow and management of DFMEA / PFMEA. . Participation in team applying Value Stream Mapping to determine efficient use of machinery and labor for new business development and improvement of existing processes. For example, Toyota Corolla Door Seal. . Participation as Champion at work by applying 6-Sigma to solve problems and improve the extrusion lines, to reduce scrap and increase productivity. . Benchmarking with other plants of Corporation, seeking an exchange of technology to best practices in processes of extrusion and finishing cells. Development application process online Coating to reduce the waste generated in off-line application process. . Responsible for the implementation of improvements in the extrusion lines flocked to avoid losses and reduce costs. . Application of DOE to define the best process parameters. . Develop suppliers of machinery and equipment components for domestic and import. Participated in the implementation of the "6-Sigma - Lean Manufacturing" as a member of the Continuous Improvement group dedicated to getting hold of work 6-Sigma and Lean Manufacturing. . Deployment of "Kanban" in the whole factory in order to reduce inventory and improve communication between the production areas. . Programmed and performed several works of Kaizen providing 20% of the workforce for new businesses and various equipment such as extrusion lines, presses and finishing machines. . Participated in the Deployment with the group's Continuous Improvement Plan Tip molded to the 6-Sigma concepts that rewards employees who submit ideas that bring the economy or cost reduction for the company. This Plan Tip resulted in savings of approximately 3% of revenues. -
Process EngineerMangels Sep 1994 - May 1999. Production Coordination, Technical and Administrative Service Units Renewal containers for LPG - Units of Duque de Caxias-RJ and Canoas-RS. Responsible for managing production, logistics, materials, equipment maintenance, technical assistance and contact with all clients of the unit, namely: Liquigas, Supergasbrás, Shellgás, etc. . Development and coordination of processes to low pressure casting of aluminum wheels. . Development of application of the ceramic tube fisherman injection of aluminum. . Participation in projects to reduce costs and content of scrap metal castings, as well as recovery of parts refugees. . Implementation of technology in blast furnaces, and realization of start-up of foundry equipment. . Rationalization of energy in the smelting and minimization of oxides in castings. . Participation in the automation of injection molding machines to low pressure. . Implementation of CEP, the ISO 9000 and the concept - education program for quality. . Participation in the implementation of the QS 9000 standard in the foundry industry Mangels. . Use of different methodologies for testing and controls, such as destructive testing, liquid penetrate, Ultra Sound, visual and dimensional control. . Technical supervision and administrative teams. -
Development Process EngineerCosipa Mar 1990 - Aug 1994Area of Activity: Manufacturer of Sheet and Coil Steel of Hot and Cold. 16,000 employees. . Participation in groups to minimize the loss of efficiency of equipment by applying the method of problem solving - TQC. . Coordinator of the assembly of cintadeira automatic coil line strips of the hot. . Coordinating development and use of rolling mill rolls - the development of suppliers. Participation in annual planning and strategy of buying stocks and rolling mill rolls. . Coordination of work of industrial waste recycling workshops of cylinders. . Coordinator of preventive maintenance and major breakdowns of the furnaces and rolling mills line the hot strip. . Development cylinder Hi - Cr for hot rolling and cold rolling of sheet flooring. . Participated in the design of laser texturing of rolls for cold rolling. Cosipa - Lasertech - unicamp . Participated in the implementation of G.S.P. (Group Problem Solving), based on the MASP.
Rogerio Carvalho Skills
Rogerio Carvalho Education Details
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Gestão Empresarial -
Metalurgical Engineering
Frequently Asked Questions about Rogerio Carvalho
What company does Rogerio Carvalho work for?
Rogerio Carvalho works for Corbion
What is Rogerio Carvalho's role at the current company?
Rogerio Carvalho's current role is CI Manager @ Corbion | Lean Methodologies, Resource Planning.
What is Rogerio Carvalho's email address?
Rogerio Carvalho's email address is rc****@****.com.br
What schools did Rogerio Carvalho attend?
Rogerio Carvalho attended Fgv - Fundação Getulio Vargas, Universidade Federal Fluminense.
What skills is Rogerio Carvalho known for?
Rogerio Carvalho has skills like Kaizen, Lean Manufacturing, Six Sigma, Ts16949, Continuous Improvement, Automotive, 5s, Manufacturing, Injection Molding, Kanban, Value Stream Mapping, Fmea.
Who are Rogerio Carvalho's colleagues?
Rogerio Carvalho's colleagues are Font Nati, Amilton Brito, Watcharanuj Panuthad, Linda Kelly, Ricardo Godtschalk, Charlie Mclean, Badre Nouar.
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Rogério Carvalho
Palmas, To1gmail.com -
Rogerio Carvalho
Operations Director | Country Manager | C-Level | P&L | Sales | Business Development | StrategyMacaé, Rj -
Rogério Carvalho
Macaúbas, Ba
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