Carolina Segundo

Until March 2024 I maintained the same responsibilities as in the VSM role, but additionally I was interim of the position of Director of Operations, responsibility shared with another Value Stream Manager. Since March, I am focused in strategic projects in the Operations area, concentrated on improving key business indicators such as Efficiency and Absolute Adherence, leading RCCMs of diverse supply chain issues such as raw material shortages and monitoring on time execution of Special Orders.

- Managed and coordinated all business unit production operations, ensured efficient collaboration and co-ordination between departments.

- Lead a team of 875 direct reports (48 manufacturing cells).

- Supervised production team to execute production plan at the right cost and level of quality, ensuring that health and safety regulations were met.

- Reported in a daily basis to the upper management the production metrics as Schedule Adherence, Attainment, Scrap, Product Availabilty, Back Order, WIP Inventory Value, Inventory Accuracy, HC, Absorption, Training Compliance, etc.

- Maintained NCMR metric under control.

- Implemented a supermarket and re-designed a manufacturing line layout, achieving 30% efficiency increase.

- Conducted meetings with floor personnel and interdisciplinary teams to solve problems and brainstorm on improvement projects, engaging support teams.

- Direct Labor Certification program implementation to reduce turnover and develop talent.

- Managed production budget.

- Responsible for the Recruitment and Organizational Development Team.

- Worked with managers to identify training needs and map out development plans for teams and individuals.

- Responsible for managing, designing, developing, coordinating and conducting all training programs.

- Onboard new hires and train them in our policies and procedures.

- Training Facilitator. The 5 Choices to Extraordinary Productivity Facilitator.

- Directed all recruitment efforts and processes.

- Worked with value stream managers to confirm hiring needs and requirements.

- Organized and led the Ideal Profile Project, psychological testing used for direct labor recruitment in order to reduce turnover and absenteeism. Voluntary Turnover decreased from 7% to 4.5%. Absenteeism decreased from 3.5% to 3.0%.

- Participated in DJO Talent-Based Hiring Strategy as the gallup assessment implementation and the competency based interviewing.

- Inclusion Program Leader. Obtained Inclusive Company Recognition from STPS.

- Lead focus groups, GPTW and new hire satisfaction surveys.

- Lead goal setting, performance review, talent alignment (9 box) and budget process.

- Supervised production team to manage and execute production plan at the right cost and level of quality, ensuring that health and safety regulations are met.

- Supervised 30 cells and a 800 staff.

- Responsible for communicating and meeting daily production requirements.

- Reported in a daily basis to the upper management the production metrics as the Schedule Adherence, Attainment, Scrap, Efficiency, etc. The YTD Attainment from Upper Extremity (Procare) increased from 85% to 94%.

- Lead root cause analysis for top offenders per metric.

- Executed Successful recovery plans for several cells.

- Managed the ramp of a weekend shift on Exos manufacturing line, increasing capacity from 6K a week to 10K a week. Hiring and training sewing personnel and managing a very aggressive timeline, recovering from a very serious back order situation.

- Identified and planned for resources needed to accomplish production objectives.

- Conducted meetings with floor personnel and interdisciplinary teams to solve problems and brainstorm on improvement projects, engaging support teams.

- Promoted Lean Manufacturing practices to eliminate waste and non-value added time. Worked with OPEX team in the implementation of daily management systems (Tiers) and 5's strategy, lead the set-up wheel initiative to reduce set-up time, lead and participated in several Kaizen events, etc.

- Guided and supported supervisors on all discipline and corrective action matters.

- Analyzed attrition and absenteeism trend.

- Reviewed inventory value trend by location and part number detail.

- Responsible for improving the performance of cells. At Module 12 increased production from 20K units to 28K units per day, working with engineering in a line balancing project and reducing the downtime related to warehouse delays.

- Supervised production team to execute production plan at the right cost and level of quality, ensuring that health and safety regulations are met.
- Supervised 6 cells and a 115 staff.
- Responsible for communicating and meeting daily production requirements.
- Reported in a daily basis to the upper management the production metrics as the Schedule Adherence, Attainment, Scrap, Efficiency, etc.
- Responsible for improving the performance of cells.

Completed a production line transfer from Minnesota, managing the project timeline and ensuring that the critical activities were executed in time, as the new equipment validations and the employee training in the new processes.

- Worked with cross-functional teams to introduce new products on time, according to the committed date with customer.

- Technical interface between the development team and the production side.

- Listed costs involved in production.

- Assisted QA to setup quality standards.

- Once the Engineering Change Request (ECR) was received uploaded the new skus in glovia system (BOM, routing, carton file).

- Responsible of creating work instructions.

- Lead Continuous Improvement Kaizen Events for Manufacturing Systems.

- Collaborated with Purchasing in the purge-disposition process.

- Implemented productivity projects.

- Designed tooling for label's converting process.

Design, optimize and monitor the manufacturing process in Labels business unit. Participate as leader for several kaizen events such as SMED, GTA, etc. Implement and track OEE metric and follow up improvement activities on a PDCA and project A3.

Design new products or improve existing products; apply lean manufacturing and six sigma tools in order to improve project management; train operations on new products; identify materials needed for production; order, track and expedite materials and tooling required for projects; write trial reports and perform product/lab testing.

Performed converting trials and product/lab testing, assist the Product Development Eng. on product validations and expedited materials and tooling required for trials.

Audited BOM's, developed visual aids, work instruction sheets and product specifications.

Supported direct personnel recruiting process, new hire orientation and external promotion.