Gustavo Rodríguez Tapia
Regional Continuous Improvement & Operational Excellence Leader
Monterrey, Sonora,NLE
Summary
Continuous Improvement and Operational Excellence executive with 20+ years of experience driving sustainable performance across automotive and packaging industries. Proven track record in leading regional CI programs, deploying Lean Six Sigma methodologies, and aligning operational initiatives with business goals. Certified Master Black Belt with global exposure (Mexico, US, Germany, Colombia), adept at standardizing processes, coaching cross-functional teams, and delivering $5M+ annual savings. Passionate change agent fostering a culture of excellence and continuous learning.
Overview
22
22
years of professional experience
5
5
Certifications
2
2
Languages
Work History
Technical & Operational Excellence Sr Manager Mexico
Smurfit Westrock
01.2023 - Current
- Implemented operational standards across 11 Consumer Packaging plants in Mexico through structured training and evaluations, driving measurable improvements in machine productivity (up to 12% OEE increase in key assets).
- Led and managed Cost Take Out (CTO) initiatives, identifying and executing over 130 projects, achieving cumulative savings of $3.3M USD from January to May 2025. Provided hands-on training on loss analysis methodologies and project execution using internal platforms aligned with financial targets from the Consumer Packaging VP.
- Coordinated the deployment of the Operational Excellence Model, based on Smurfit Westrock Mexico's standard framework, resulting in the harmonization of processes across sites and increasing process maturity index scores by 15% in the first year.
- Trained and certified more than 50 team members through the Lean Six Sigma Belts program (Yellow, Green, and Black), fostering a culture of continuous improvement and developing internal capabilities to sustain excellence.
Operational Excellence Sr Manager
Westrock
01.2023 - Current
- Responsible for deploying the Operational Excellence Program across 7 Consumer Packaging plants in Mexico.
- Led the implementation of the Daily Management System (WOR, DOR, SHOR) across all sites.
- Delivered $5.5M in CI savings (FY24) by coaching plant teams on CI methodologies and project execution.
- Certified 90+ Lean Six Sigma Belts through structured training and mentoring.
- Acted as strategic partner to BU leadership, aligning initiatives with KPIs in Safety, Quality, Cost, and Service.
Planning and Production Control Manager
Clarios
01.2021 - 01.2022
- Company Overview: formerly Johnson Controls
- Managed Planning, Scheduling, Shipping, Raw Materials, and Spare Parts Warehouse ($12M value).
- Led S&OP process and coordinated 49 hourly and 4 salary staff.
- Held Interim Plant Manager role (260 hourly + 60 salary personnel).
Operational Excellence Manager
Clarios
01.2018 - 01.2021
- Led the cultural transformation toward Operational Excellence at plant level.
- Deployed Clarios Manufacturing System 2.0: TPM, Kaizen, High Performance Teams, Gemba, 5S, DMAIC, Innovation, and Digital Tools.
- Coached Six Sigma and Lean projects, aligning initiatives with EHS, People, Quality, Service, Productivity and Cost KPIs.
- Exceeded yearly savings targets of $2.5M through strategic project selection and team development.
- Trained entire plant staff in Lean and problem-solving tools by role.
Master Black Belt / Sr Master Black Belt
Clarios
01.2013 - 01.2018
- Regional CI Leader for 3 plants (Lead Recycling, Injection Molding, Grid Stamping).
- Trained and certified 30+ Black Belts and 100+ Green Belts across Mexico and Colombia.
- Supported Directors and Managers through Champion Training and Executive Coaching.
- Achieved over $2M annual savings and multiple global recognition awards for best practices.
- Led Global Best Practice Workshop with 5 Recycling plants and coordinated benchmarking across US, Mexico, Germany.
Six Sigma Black Belt / Sr Black Belt
Johnson Controls
01.2010 - 01.2013
- Led 12+ DMAIC projects in operations using Six Sigma and Lean Tools.
- Awarded 1st place in Americas Practice Rally 2012 (Breaker throughput project).
- Generated $1M in annual savings by reducing antimony usage in Refining.
Industrial Engineer
Johnson Controls
01.2007 - 01.2010
- Implemented headcount and productivity analysis tools for Recycling operations.
- Deployed TPM basics and supported continuous shift operations implementation.
Lean Implementer & Production Scheduler
ProezaGREDE / NovoCast
01.2004 - 01.2007
- Scheduled production and managed shipping and warehouse operations.
- Supported Lean deployment in automotive Tier 2 die casting operations.
Education
MBA - Management (Finance)
Universidad Autónoma de Nuevo León
Bachelor of Science - Industrial Engineering
Universidad Autónoma de Nuevo León
Skills
- Operational Excellence Strategy
- Lean Six Sigma (DMAIC, Kaizen, TPM)
- CI Program Deployment
- Global Best Practices
- Manufacturing Systems (Clarios, JCMS)
- Digital Transformation
- Talent Development & Coaching
- Cross-functional Leadership
- Supply Chain Optimization
- Financial Impact ($MM Savings)
- Minitab
- Microsoft Excel
- Power BI
Certification
Lean Six Sigma Master Black Belt – Johnson Controls
Accomplishments
- Achieved [Result] by completing [Task] with accuracy and efficiency.
Timeline
Technical & Operational Excellence Sr Manager Mexico
Smurfit Westrock
01.2023 - Current
Operational Excellence Sr Manager
Westrock
01.2023 - Current
Planning and Production Control Manager
Clarios
01.2021 - 01.2022
Operational Excellence Manager
Clarios
01.2018 - 01.2021
Master Black Belt / Sr Master Black Belt
Clarios
01.2013 - 01.2018
Six Sigma Black Belt / Sr Black Belt
Johnson Controls
01.2010 - 01.2013
Industrial Engineer
Johnson Controls
01.2007 - 01.2010
Lean Implementer & Production Scheduler
ProezaGREDE / NovoCast
01.2004 - 01.2007
Bachelor of Science - Industrial Engineering
Universidad Autónoma de Nuevo León
MBA - Management (Finance)
Universidad Autónoma de Nuevo León
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