Juan Santos

Top performance servant leader with over 25 years of experience developing result driven processes and top talent people. 

JUAN CARLOS SANTOS

TOP-PERFORMING GENERAL OPERATION MANAGER

 Manufacturing Manager • Operations Director • Director of Operations • Plant Manager

Process Standardization • Quality Control • Strategic Planning • Process Improvements

 Reduced Downtime • Increased Throughput • Decreased Costs • Streamlined Processes

Minimized Labor • Optimized Resource Allocation • Implemented Lean • Enhanced Quality Control

WORK EXPERIENCE

Pro-Tops Inc (Building Materials); Monroe, NC

International Operations General Manager                                                 August 2023 - Present

●      Implemented Lean Manufacturing in all 4 plants (Cabinet Division, Stone Division, Culture Marble Division and Brazil Division) Reducing their lead time, lowering labor from 38% to 23%, and reducing their total remakes from 4.6% to 0.5%. This was a total of 4.5 million in saving cost and a close to a six-sigma level. Very hard to accomplish in a stone countertop industry.

●      Eliminated all Osha safety concerns and violations.

●      Introduced TWI to the leadership team to deliver effective training.

●      Implemented step by steps standard work.

●      Implemented Visual Management to the shop floor and office personnel.

●      Implemented score card (EOS) for the CEO and COO of the company.

●      Reduced Inventory and materials issues saving the company over 250k a year.

●      Implemented All KPI’s in the organization.

●      Lower Overhead cost by Restructuring the whole organization and direct reports.

●      Developed Vision, Mission and Core Values.

●      Help with the implementation of 10X (Cardone)

E.T.A Lean Manufacturing Contracting; Indian Trail, NC                           March 2023 – August 2023

SR. Vice President/Integrator

●      Deliver VSM (Current State and Future State) for different Client Projects.

●      Deliver 5’s training and implementation for different Clients.

●      Help with CAPA’S, Developed TQM, Root Cause analysis, and delivery training for different Clients.

●      Create Standard work, lead standard work, audits and training for Different Clients.

●      Help reduce waste, improve output by 30% (guarantee) and reduce real estate for Different Clients.

●      Lead Sales for current and future clients.

●      Deliver training for effective Gemba walks.

●      Create and deliver Effective Visual Boards, train to effective use of Visual Boards and how to address Action Items.

2 Hounds Design (Textile); Indian Trail, NC                                             February 2017 – March 2023

Manufacturing General Manager/Integrator

●      Drove nearly a 90 % reduction in downtime by developing TPM on all equipment.

●      Achieved a 65% reduction in shop floor labor through Kaizen events, creating a new and simple process by using creativity vs. capital.

●      Propelled a 60% growth company by working with the President on strategies to increase sales, providing training to the sales team, and focusing on marketing strategy.

●      Championed a 51% increase in output, reducing lead time from 3 weeks to 3 days.

●      Secured a 37% decrease in material cost by developing vendor relationships, improving yields, and buying directly from the manufacturer.

●      Supervised 6 direct reports, including the Production Manager, the HR/Safety Manager, the Customer Service Manager, and the Maintenance Supervisor.

●      Supported weekly level 10 meetings, quarterly meetings, and annual meetings, keeping the team on track with the company's objectives.

●      Implemented EOS in the company, defined core values, core focus, 1-, 3- and 5-year targets, set up quarterly rocks, and led level 10 meetings.

●      Decreased lead times by designing and implementing a new machine.

●      Teamed up with vendors to reduce lead times by writing material specifications.

●      Oversaw P&L and capitalized on opportunities for improvement.

●      Monitored sales trends and adjusted labor and inventory accordingly.

●      Facilitated all the lean activities and Kaizen events in the plant.

●      Mastered the intricacies of the process flow within each department.

●      Assessed and trained personnel for promotion to cross-functional operations.

●      Developed and implemented data-based solutions promptly.

●      Changed the culture of the plant by gaining trust and continuous training in Lean manufacturing.

●      Developed a TQM system to track opportunities and develop the team to identify the root cause and eliminate bottlenecks and issues.

●      Reported directly to the CEO/ President, filling in for executive decisions during absences.

●      Reconstructed the Human Resources department by developing new policies, and a new onboarding system and assisted with selecting the correct payroll company.

●      Improved to a six-sigma level on rejects and a company having only .03%

Decore-Ative Specialties (Building Materials); Monroe, NC                               June 2003 - Feb 2017

Operation Manager

●      Drove a 90% reduction in customer complaints and rejects, and shortened lead times from 6 days to 1 day through continuous improvements and Kaizen events.

●      Netted a 58% reduction in packaging damage.

●      Secured a 15% increase in efficiency by taking on new responsibilities.

●      Increased wood yields by 10% by creating the use of scrap material into useful material, achieving the #1 ranking among all plants.

●      Achieved 0.16% rejections, the best in the company.

●      Oversaw the daily planning and direction with 6 direct reports that included 2 Area Managers, 3 production supervisors, and 1 CI coordinator while reporting directly to the general manager.

●      Supervised 3 lines and achieved 1,900 working days accident-free.

●      Presided over a building with 6 different products which 2 were new products in the company accomplishing great results and customer satisfaction with 0 defects.

●      Reduced lead times on the thermofoil doors department by reducing waste and improving the flow from the routers to the press.

●      Monitored sales trends and adjusted labor accordingly.

●      Ensured that all Lean manufacturing processes, principles, maintenance, quality, and safety standards were adhered to.

●      Facilitated daily meetings related to new product development, and inventory.

●      Monitored and analyzed monthly P&L reports, and scheduled events to improve the bottom line.

●      Developed SPC charts as part of total quality management efforts.

●      Secured new business by developing new RTF cabinets.

●      Improved quality to a six-sigma level, having only 0.02% rejects.

Prior Experiences: Cooper Vision, Inc., Operator, Quality Assistant

EDUCATION

Pontifical Catholic University, Ponce, PR

2 Years of my bachelor’s degree, Criminology

Inter American University, Ponce, PR

3 Years of my bachelor’s degree, Operation Management

TECHNOLOGIES, LANGUAGES, & PROFESSIONAL DEVELOPMENT

Technologies: Microsoft Office, MRP, ERP, Windows

Languages: Spanish, Italian, English

Professional Development: Lean Six Sigma Certification

Proven leader by proactive serving others and developing to become better every single day. Continuous improvements is not only the process but as an individual too.