Hi, I’m
Juan Ernesto Herrera Limones
Monterrey
Summary
Experienced Plant Manager adept at improving output, maximizing quality and boosting employee satisfaction with hands-on management style. Recognized as effective business manager and motivational leader. Successful manufacturing management career spanning 18 years with expertise in cost controls, lean manufacturing principles and employee training on metal-mechanic Industry.
Overview
18
years of professional experience
1
Certification
Work History
Babcock & Wilcox De Monterrey
Plant Manager
05.2022 - Current
Job overview
- Led, trained and coached plant staff to facilitate high levels of productivity and quality.
- Reduced costs by eliminating materials waste and unnecessary labor hours.
- Maximized plant safety through proactive strategies and well-structured training.
- Created plant policies and procedures for safe and productive operations.
- Monitored and evaluated plant performance to identify areas for improvement and take corrective measures.
- Provided direction and leadership to all levels of employees and managers.
- Identified and implemented viable strategies for continuous improvement.
- Managed direction and planning for plant with focus on optimization of daily functions, exceeding customer expectations, and achieving KPIs.
- Promoted collaborative work environment to motivate and engage staff to achieve company objectives.
- Oversaw daily operations of 1,217,398 sq. ft. manufacturing plant.
- Devised and administered cost control initiatives saving $ 11.3 mMXN ($665 kusd) .
- Trained in and implemented emergency response procedures to protect team members and property.
- Planned operations to meet established schedules, factoring in order demands and business forecasts.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Evaluated employee performance and provided feedback and training as needed.
- Enforced health and safety protocols to promote safe working environment.
- Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
- Maintained quality of product with robust inspections and assessment team.
- Identified and resolved process and equipment issues to minimize production downtime.
Caterpillar Industries México
Production General Manager
02.2021 - 05.2022
Job overview
- Resolved issues quickly to maintain productivity goals.
- Reviewed work for quality and compliance with company standards and design specifications.
- Standardized production procedures, job roles, and quality assurance guidelines.
- Managed internal operational standards and productivity targets.
- Managed continuous improvement initiatives to drive gains in quality, flow, and output.
- Estimated labor requirements to support anticipated workload.
- Partnered with leadership on recruiting, hiring and coaching production personnel.
- Delivered direct feedback to senior management regarding project visibility and status.
- Determined suitable crew requirements, scheduled employees, and worked with human resources to meet changing production schedules.
- Created streamlined production schedules and collaborated with production employees to communicate objectives and goals.
- Reviewed maintenance and repair problems to determine appropriate action for resolution.
- Monitored team budgets to keep projects on task and avoid waste.
- Wrote and conducted formal performance reviews for production personnel.
- Created and oversaw production schedules and adjusted as needed to meet deadlines.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
- Coordinated with other departments to align production with customer requirements.
- Enforced health and safety protocols to promote safe working environment.
- Planned operations to meet established schedules, factoring in order demands and business forecasts.
- Prepared and maintained production reports and personnel records.
- Scrutinized production output and identified areas for improvement.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Analyzed production data and prepared reports for senior management.
- Implemented quality control system to review products against technical specifications and corporate standards.
- Utilized data analysis tools to identify and resolve production issues.
- Devised and administered cost control initiatives saving $660 kusd in one year.
Caterpillar Industries México
Quality Manager
06.2018 - 02.2021
Job overview
- Managed and archived quality documentation and participated in internal and external quality audits (ISO9001-2015).
- Coordinated and oversaw periodic audits to evaluate product quality and safety and address non-conformances.
- Increased customer satisfaction through adherence to quality standards and customer requirements.
- Evaluated quality problems and performed assessments to identify and resolve issues.
- Updated quality control standards, methods, and procedures to meet compliance requirements (PPMs from 2,450 in 2017 to 397 in 2018).
- Followed quality standards and procedures to minimize errors and maximize customer satisfaction (BIQ implementation).
- Wrote and implemented new rework procedures to standardize processes and streamline workflow (NCM, run-off/Prove-out process, CNC Machines, CNC programs and Fixtures Certification process, 4th quadrant certification program for workers .
- Improved quality processes for increased efficiency and effectiveness. Scrap reduction in 30%.
- Mentored and encouraged employees to strive for excellence while fostering professional growth.
- Developed and deployed production control plans and created work instructions and procedures.
- Calibrated instruments and scales in production area and quality lab.
- Equipped and organized facility to comply with company strategy for online and offline quality controls.
- Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.
- Opened and closed location and monitored shift changes to uphold successful operations strategies and maximize business success.
- Evaluated employee performance and conveyed constructive feedback to improve skills.
- Defined clear targets and objectives and communicated to other team members.
- Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement.
- Trained personnel in equipment maintenance and enforced participation in exercises focused on developing key skills.
- Leveraged data and analytics to make informed decisions and drive business improvements.
Caterpillar Industries México
Operations Group Manager II
05.2016 - 05.2018
Job overview
- Supervised operations staff and kept employees compliant with company policies and procedures.
- Developed systems and procedures to improve operational quality and team efficiency.
- Managed inventory and supply chain operations to achieve timely and accurate delivery of goods and services.
- Led hiring, onboarding and training of new hires to fulfill business requirements.
- Established positive and effective communication among unit staff and organization leadership, reducing miscommunications, and missed deadlines.
- Analyzed and reported on key performance metrics to senior management.
- Identified and resolved unauthorized, unsafe, or ineffective practices.
- Introduced new methods, practices, and systems to reduce turnaround time.
- Implemented process improvement to shape organizational culture, optimize procedures for higher efficiency and help company evolve and grow.
- Increased profit by streamlining operations.
- Trained new employees on proper protocols and standards for a start-up facility.
- Trained and guided team members to maintain high productivity and performance metrics in a start-up facility.
- Assisted in recruiting, hiring and training of team members for a start-up facility.
- Observed each employee's individual strengths and initiated mentoring program to improve areas of weakness.
- Reported issues to higher management with great detail.
- Launched staff engagement, gender diversity and cultural programs in addition to robust reporting tool that increased operational quality.
Caterpillar MexicoMonterrey, Nuevo León
Operations Group Manager I
04.2015 - 05.2016
Job overview
- Skilled at working independently and collaboratively in a team environment.
- Self-motivated, with a strong sense of personal responsibility.
- Proven ability to learn quickly and adapt to new situations.
- Worked well in a team setting, providing support and guidance.
- Passionate about learning and committed to continual improvement.
- Proved successful working within tight deadlines and a fast-paced environment.
- Strengthened communication skills through regular interactions with others.
- Organized and detail-oriented with a strong work ethic.
- Used critical thinking to break down problems, evaluate solutions and make decisions.
- Paid attention to detail while completing assignments.
- Identified issues, analyzed information and provided solutions to problems.
- Participated in team projects, demonstrating an ability to work collaboratively and effectively.
- Cultivated interpersonal skills by building positive relationships with others.
Caterpillar MéxicoMonterrey, Nuevo León
Quality and Continuous Improvement Manager
03.2014 - 04.2015
Job overview
- Managed development and implementation of lean and continuous improvement manufacturing initiatives across production environment.
- Implemented lean production methods and OQL to reduce waste by 25% (PPMs, Scrap Cost, FPY, CPKs).
- Changed existing processes and implemented new processes to improve efficiency by 30%.
- Worked with cross-functional plant teams to develop and implement manufacturing processing improvements and drive quality mindset resulting in 15% increase in productivity (Labor Ratio in First Ops.), 50 % increase in throughput (LD welding area from 2 to 3), and 35 % improvement in productivity (FPY increment from 60 % to 95%).
- Improved First Ops and LD welding process to meet company goals for earnings, quality and completion.
- Developed Continuous Improvement/Lean production training programs for onsite implementation.
- Mentored and coached Six Sigma Green Belts in lean manufacturing and continuous improvement processes.
- Developed custom value stream mapping to monitor production efficiency.
- Led efforts in analysis and design of more cost-effective processing technology to improve current Cutting (Plasma) manufacturing systems.
- Applied coaching techniques and tools to support managers and team members in improving performance.
- Tracked quality issues with external customers, suppliers, and internal plant operations.
- Assured consistent quality of production by implementing and enforcing UT, MT, PT and visual inspections practices.
- Determined quality department standards, practices, and procedures.
- Scheduled and chaired quality review meetings to review effectiveness of performance mitigating risk, improving throughput and achieving customer satisfaction (Quality Council).
- Developed quality planning for multiple new product launches by verifying customer requirements and implementing in design and production.
- Collaborated with audit clients and action owners to apply root cause analysis guidance and establish effective corrective action plans.
Caterpillar MéxicoMonterrey, Nuevo León
Lean and Six Sigma Black Belt
02.2012 - 03.2014
Job overview
- Analyzed project performance data to identify areas of improvement.
- Tracked project and team member performance closely to quickly intervene in mistakes or delays.
- Reported regularly to managers on project budget, progress and technical problems.
- Scheduled and facilitated meetings between project stakeholders to discuss deliverables, schedules and conflicts.
- Monitored project progress, identified risks and took corrective action as needed.
- Maintained open communication by presenting regular updates on project status to customers.
- Facilitated workshops to collect project requirements and user feedback.
- Recruited and oversaw personnel to achieve performance and quality targets.
- Skilled at working independently and collaboratively in a team environment.
- Self-motivated, with a strong sense of personal responsibility.
- Worked effectively in fast-paced environments.
- Passionate about learning and committed to continual improvement.
Caterpillar TorreónTorreón Coahuila, Coahuila de Zaragoza
General Supervisor of Operations
02.2010 - 02.2012
Job overview
- Resolved issues through active listening and open-ended questioning, escalating major problems to manager.
- Hired, managed, developed and trained staff, established and monitored goals, conducted performance reviews and administered salary grades for staff (UH and MS).
- Coordinated individual duties after careful evaluation of each employee's skill level and knowledge.
- Improved SPQVC KPIs (customer satisfaction) scores through application of superior conflict resolution and problem-solving skills.
- Implemented project management techniques to overcome obstacles and increase team productivity (SMED for bending area).
Caterpillar TorreónTorreón Coahuila, Coahuila de Zaragoza
Section Manager III
04.2008 - 02.2010
Job overview
- Identified section KPIs and created measurement mechanism to track operations efficiency.
- Assigned employees to ongoing and special projects to realize adequate staffing and meet production schedule parameters.
- Delivered weekly project updates to management to enhance program visibility and promote improved project performance.
- Scheduled weekly section meetings to review emerging challenges, identify opportunities and recognize high-performing employees.
- Conducted annual employee performance reviews to recognize achievements and identify areas needing improvement.
- Improved quality to enhance operations efficiency.
- Executed quality assurance audits and addressed non-complying issues to improve section performance.
- Resolved customer service escalations to promote mutually beneficial outcomes.
- Compared production costs to budgetary guidelines and adjusted variables to achieve budget compliance.
- Monitored production schedules and made adjustments to achieve compliance with preset timelines.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Enforced health and safety protocols to promote safe working environment.
- Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
- Coordinated with other departments to align production with customer requirements.
- Utilized data analysis tools to identify and resolve production issues.
- Collaborated with technical and administrative teams to develop and implement successful corrective plans.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Created and oversaw production schedules and adjusted as needed to meet deadlines.
- Evaluated employee performance and provided feedback and training as needed.
- Devised and administered cost control initiatives saving >$ 285 Kusd (Scrap cost, perishable tools, Mtce cost, Labor cost).
- Analyzed production data and prepared reports for senior management.
- Implemented quality control system to review products against technical specifications and corporate standards (Operator Self Inspection Qualification & Certification).
- Planned operations to meet established schedules, factoring in order demands and business forecasts.
Caterpillar TorreónTorreón Coahuila, Coahuila de Zaragoza
Section Manager I
03.2007 - 04.2008
Job overview
- Identified section KPIs and created measurement mechanism to track operations efficiency.
- Assigned employees to ongoing and special projects to realize adequate staffing and meet production schedule parameters.
- Scheduled weekly section meetings to review emerging challenges, identify opportunities and recognize high-performing employees.
- Executed quality assurance audits and addressed non-complying issues to improve section performance.
- Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials.
- Enforced health and safety protocols to promote safe working environment.
- Managed personnel by implementing company policies, procedures, work rules, and disciplinary action.
- Collaborated with technical and administrative teams to develop and implement successful corrective plans.
- Oversaw routine maintenance programs and scheduled service to keep equipment functioning at peak levels.
- Prepared and maintained production reports and personnel records.
Caterpillar TorreónTorreón Coahuila, Coahuila de Zaragoza
Suppliers Quality Development
02.2006 - 03.2007
Job overview
- Approved incoming materials by confirming specifications and taking measurement tests.
- Documented inspection results by completing logs.
- Inspected incoming products for adherence to labeling laws and company quality standards.
- Created and maintained several databases to track statistical data.
- Planned and implemented performance improvement and quality assurance programs.
- Minimized down time 12% by reducing production rework and recalls (Improve Suppliers Delivery Performance in 25 %).
- Suggested improvements to designs and documentation to improve product reliability and manufacturability.
- Instructed vendors on quality guidelines, safety procedures, testing procedures and ways to eliminate deficiencies.
- Created and oversaw production schedules and adjusted as needed to meet deadlines.
- Coordinated with other departments to align production with customer requirements.
- Analyzed production data and prepared reports for senior management.
- Implemented quality control system to review products against technical specifications and corporate standards.
Caterpillar TorreónTorreón Coahuila, Coahuila de Zaragoza
Supplier Quality Engineer
04.2005 - 02.2006
Job overview
- Maintained amiable relationships with suppliers through difficult quality control issues, supporting healthy business interactions.
- Analyzed issues with supplier contributions to detect defect trends, reporting findings to appropriate personnel.
- Conducted supplier audits to detect pre-production weaknesses in supply chain and human resource assets.
- Set up ongoing supplier site evaluation parameters to maintain quality control standards over long-term relationships.
- Designed inspection plans and methods for execution by personnel at remote locations, verifying accurate implementation and data collection.
- Resolved supplier quality control issues through collaboration with third-party leadership.
- Drafted instructional documentation for distribution to suppliers to establish standardized performance and quality thresholds.
- Led commodity-related quality control issues, correcting functional issues stemming from problematic components.
- Traveled to assigned supplier facilities to verify supplier staff qualifications via multiple modes of inspection and investigation.
- Led root cause analyses to identify and address problems in industrial production.
- Collaborated with cross-functional teams to develop and implement process changes.
Education
UDEMSan Pedro Garza García, Nuevo León
M.D. from Engineering Management Master Degree
12.2021
University Overview
- Professional Development Studies: Management Skills Diploma, 2023
COMIMSASaltillo Coahuila
Welding Specialist from Metallurgical Engineering
02.2015
Instituto Tecnologico De La LagunaTorreón Coahuila
Mechanical Engineer from Materials, Energy, Fluids, Heat Transfer.
08.2004
Skills
- Maintain Quality Standards
- Equipment Installation
- ACE Tools Familiarity
- Customer Expectations Management
- Facility Maintenance
- Lean Manufacturing Processes
- Total Quality Management
- Employee Performance Reviews
Accomplishments
- Achieved > 614,400 work hours with any recordable injury for Hourly people through effectively Safety standards and practices reinforcement and improving.
- Recertification in ISO9001-2015 through monitoring of the standards documentation in the plant and their improvement.
- NCRs reduction in > 25% YTY through highly visibility for quality results in a daily basis by GEMBA walks.
- Achieved automatic reporting of man hours by introducing SAP for production.
Certification
- Management Skills Certification, TECMI - Jul-2023 to Sep-2023.
- CQI, ASQ - Jun-2014 to Oct-2014.
- Six Sigma Black Belt, Caterpillar México - Aug-2011 to Nov-2011.
Languages
English
Advanced (C1)
Timeline
Plant Manager
Babcock & Wilcox De Monterrey
05.2022 - Current
Production General Manager
Caterpillar Industries México
02.2021 - 05.2022
Quality Manager
Caterpillar Industries México
06.2018 - 02.2021
Operations Group Manager II
Caterpillar Industries México
05.2016 - 05.2018
Operations Group Manager I
Caterpillar Mexico
04.2015 - 05.2016
Quality and Continuous Improvement Manager
Caterpillar México
03.2014 - 04.2015
Lean and Six Sigma Black Belt
Caterpillar México
02.2012 - 03.2014
General Supervisor of Operations
Caterpillar Torreón
02.2010 - 02.2012
Section Manager III
Caterpillar Torreón
04.2008 - 02.2010
Section Manager I
Caterpillar Torreón
03.2007 - 04.2008
Suppliers Quality Development
Caterpillar Torreón
02.2006 - 03.2007
Supplier Quality Engineer
Caterpillar Torreón
04.2005 - 02.2006
UDEM
M.D. from Engineering Management Master Degree
COMIMSA
Welding Specialist from Metallurgical Engineering
Instituto Tecnologico De La Laguna
Mechanical Engineer from Materials, Energy, Fluids, Heat Transfer.
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