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Professional Profile

(Download / Print: Rene Galarza - Resume.pdf)

René Galarza

BSIE, MAHRD, CSSBB

Engineering & Management - Operations

Process Analysis & Re-Engineering / Lean - Sigma Production Systems / Cellular Production 

Pull Manufacturing / Warehousing & Distribution Systems / Project Management / Toyota Production System

Start-Ups & Turn-Around / Training / Materials Management / Supply Chain Development

Cost Reductions / Change Management / Process-Quality Control / Production Facility Design

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CORE STRENGTH

Directing the design, implementation and management of efficient production and distribution operations by the application of progressive industrial management & engineering techniques and organizational development.  Turning around poor production performance by coaching and training management staff and production teams on continuous process improvement, lean - sigma disciplines, material control systems and change management.

CAREER SUMMARY

Senior multi-lingual executive with experience in successful organization development and growth.  Blue Chip background includes Storage Technology, Texas Instruments, Compaq, EAS and Mackie Designs.  Expert at increasing efficiencies, reducing costs, troubleshooting, resolving problematic operations, managing change and leveraging technology to provide a competitive business advantage.  Experienced in production environments specializing in manufacturing, warehouse and distribution center start-ups and reengineering, and in the development of performance improvement programs.  Working knowledge in all aspects of industrial engineering, production management and organizational development:

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Flexible Facility Designs

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Lean Process Development

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Cellular Manufacturing Design

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Team Building / Facilitation

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Organizational Development

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Inventory Control Systems

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TPS-Pull-Kanban Mfg. Systems

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Technical & Leadership Training

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Occupational Ergonomics

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Process Flow Analysis & Optimization

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Material Handling: Distribution/Storage

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Engineering-Assembly Line Management

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Performance Improvement Programs

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Project Planning & Management

QUALIFICATIONS

Knowledgeable in quality and productivity improvement techniques and systems.  Skilled in coordinating and managing program development projects.  Experienced in the planning and implementation of effective facility layouts, workstation design, work flow analysis, inventory control and distribution systems, work measurement, cost control, and performance improvement programs.  Recognized for effective system analysis and problem-solving ability. Proficient in the application of a comprehensive approach to production performance improvement by examining the business operations as a "system" taking in consideration tasks performed at the individual level, to the overall organizational structures. Effective in maximizing the utilization and integration of resources to include facilities, personnel, inventories, equipment and information.   Highly skilled at lean process re-engineering, material management and certified as a six sigma black belt.         

Confident coach, leader and trainer.  Strong interpersonal and communication skills.   Understanding and emphatic in dealing with individual and group morale.  Great motivator.  Highly knowledgeable of team dynamics and empowerment.  Ability to positively lead the organization toward the corporate strategic direction and the attainment of goals and objectives.  Effective in implementing organizational and participatory change within the existing corporate culture.  Strong oral and writing skills.  Bilingual professional level fluency in Spanish and English.

Thorough and careful with detail.  Certified in various quality management systems as advocated by Deming, Juran, Krensky and Crosby.  Seasoned hands-on implementer of TPS, JIT and Lean Enterprise initiatives.  Technically current and proficient on productivity and quality concepts, techniques and philosophies by means of trade association membership and continued education.  Knowledgeable in many computer software applications such as CAD, spreadsheets, dynamic simulation, databases, word processors, presentation graphics, web development and utility programs.  Experienced in providing inter-cultural professional services and training, nationally and abroad.  Willing to travel extensively. 

CAREER ACHIEVEMENTS

La-Z-Boy, Inc.   2003 - 2007

Continuous Improvement / Engineering Manager

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Guided the lean operational excellence deployment in multiple facilities across the U.S.  Provided lean enterprise training and coaching to engineering staffs and lead plant management groups.  Developed and establishing lean production initiatives, strategic plans, corporate training and performance improvement.  Reported to the corporate VP of Manufacturing and VP of Continuous Improvement; La-Z-Boy, Six Production Facilities Nationwide

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Directed an engineering group as the Continuous Improvement - Engineering Manager for a ~265 employee plant: strategic planning, process development, tooling design, cost reduction, time studies, facility planning & layout and work cell installations.  Reporting to the Plant Manager and to the Corporate VP of Continuous Improvement; Lincolnton, NC.

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Led an eight-site corporate engineering team as the Engineering Project Manager in the development of the La-Z-Boy Production System.  Designed lean production cells and support systems.  Established corporate production standards.

Workplace Sciences, LLC   1997 - 2003  /  2008 - 2009

Sr. Management – Engineering Consultant / Trainer

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Coaching the corporation on lean operational practices. Developing and establishing lean production initiatives, strategic plans and performance improvement. Providing training to management staff and supervisors. Supporting the establishment of an inventory management and kanban control system;  Habersham Metal Products Co., Cornelia, GA [2008 - 2009]

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Re-engineered assembly lines and warehouse management operations.  Implemented lean initiatives that reduced production cycle time from 3.7 days to 3.1 hours, reduced work-in-process inventory by 82%, and increased production throughput by 18% without adding resources or capital equipment;  RCF, Reggio-Emilia, Italy

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Implemented a lean pull-flow manufacturing cell and trained management, engineers and production personnel on pull-flow production design, operations and support; reduced work-in-process inventory by 67 % and dropped manufacturing cycle time from 1.8 weeks to 1.7 hours;  Mackie Designs, Woodinville, WA

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Led a team in the design of a consolidated and integrated power amplifier assembly factory.  Provided consultation on lean pull-flow production systems and kanban material control;  Peavey Electronics, Meridian, MS

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Designed and implemented a 132k sq. ft. national distribution center increasing order processing efficiency and accuracy by 35%. As interim Director of Distribution developed and implemented a lean paperless inventory and order fulfillment management system, and product lot control system utilizing real-time information systems and bar code technology. Reengineered all receiving, storage, order picking, packing and shipping processes.  Raised inventory accuracy to 98.5%.  Increased same day order-to-shipment performance to 96%;  Experimental & Applied Sciences (EAS), Golden, CO

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Designed a 69K sq. ft. "Returns Management" processing facility for Direct Alliance in Tempe, AZ.  Direct Alliance is a 3PL provider supporting companies like IBM, Toshiba and other major PC OEMs with product returns management.  Product returns services were in support of the client's warranty agreements and product "repair/exchange" services; Direct Alliance, Tempe, AZ

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Improved an asset management & product returns processing center by increasing process throughput and reducing cycle time by 45%; Outsource Technologies, Denver, CO     

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Designed and installed a computer assembly & configuration production facility, including the distribution center.  Doubled the production capacity.  Project completed on time and within budget.  Received two contract awards: August ’98 & September ’99;  Compaq, Tempe, AZ

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Developed and delivered custom training programs for management and production operators on manufacturing process breakdown and on-the-job training using “Training Within Industry” techniques;  Celestica, Fort Collins, CO

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Provided factory layout design and material handling recommendations for new automated production facility; Quantum, Colorado Springs, CO

E-M-SOLUTIONS, INC.   1996 - 1997

Director of Engineering & Manufacturing

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Supported the $170M revenue growth of the 4th largest contract manufacturer in the U.S. of wire and cable, electro-mechanical assembly, and value-added services (later acquired by Sanmina).  Member of the company’s leadership team actively involved with business growth, building customer relationships and enhancing strategic positioning through improved manufacturing processes and technology.  Conducted feasibility & capability studies and technical sales presentations.  Prepared detailed responses to complex high dollar RFP/RFQ's.  Responsible for maintaining manufacturing and service costs in support of the contract - profit price point.

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Started and directed an engineering organization of 24 professionals: mechanical engineers, electrical engineers, industrial engineers, wire & cable engineers, drafters and first article-prototype technical personnel.

STORAGE TECHNOLOGY, INC.   1991 - 1996

Advisory Industrial Engineer – Consultant

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Initiated and led the Supplier Development Group providing management and engineering consulting services to supply-chain vendors.  Resolved supplier capacity, delivery, logistics, scheduling and cost escalating problems.

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Accelerated $23M in revenues by bringing a manufacturing project back from six-month production deficit. 

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Directed the development and implementation of the $3.5M flagship product manufacturing facility.

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Determined material flow requirements and installed a $1.5M automated material handling system using RFID.

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Developed detailed process specifications for inventory control and distribution systems.

TEXAS INSTRUMENTS, INC.   1980 - 1991

Lead Industrial Engineer – Manager   1984 - 1991

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Designed, implemented and supported JIT - TPS / "World Class Manufacturing" assembly factories.

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Developed production performance measurement systems for TI sites.

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Managed staff of industrial engineers and techs supporting circuit board and electro-mechanical assembly.

Production Manager   1983 - 1984

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Coached, trained, motivated, and appraised 37 employees in the wire and cable assembly facility.

Manufacturing Engineer – Supervisor    1980 - 1982

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Directed the manufacturing of sheet metal, plastics, CNC, and screw machine parts to include production scheduling, material management, cost forecasts, and supervision of manufacturing engineering technicians.

 

EDUCATION

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BS+ Industrial Engineering (BSIE), University of Puerto Rico - 1980

bulletMBA Course Work, University of Dallas - 1981-1982
bulletMaster of Arts - Human Resource Development (MAHRD), Webster University - 1993

 

PROFESSIONAL AFFILIATIONS

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Registered / Licensed Professional Engineer - PE (1984-2007) - Texas 61067

bulletPast President of the Institute of Industrial Engineers (IIE) – Rocky Mountain (CO) and Texoma (TX) Chapters.

 

OTHER QUALIFICATIONS

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Certified Six Sigma Black Belt

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Certified Project Management (PM) - Kepner-Tregoe

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Bilingual: very fluent in Spanish (read/write/speak). Can effectively interface with production plants or customers in Spanish speaking countries. Can provide training in Spanish.  Conversant in Italian.

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MTM Association for Standards and Research Blue Card Certified: MTM-1, MTM-2, 4M, MTM-V, and MTM-UAS & MTM-UAS II. Certified in Motion Time Standards.

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Certified in various disciplines as TQM (Juran, Deming, Crosby), JIT (Schonberger, APICS), MRP (APICS, Oliver Wight), SPC/SQC (Paul Krensky), Effective Negotiation (Karrass), Supervisory Development, Team Building / Dynamics and many others.

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Dynamic Simulation Software: certified in ARENA and hands-on experience with Simul8.

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PC proficient: AutoCad / MS Project / MS Word / MS Excel / MS PowerPoint / Basic programming language / Visio / Internet /  PC-Windows Utilities / LAN Systems / Web-Page Development

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Training & Development: Boulder Center for Accelerated Learning - "Dynamic Accelerated Learning System" graduate.

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Designed and delivered workshops in Occupational Ergonomics, Performance Measurement, Work Standards Development, Fundamentals of Process Training and Push vs. Pull Production Systems.

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Papers written and presented: "Workplace Team Codependency", "Intercultural Training", "Dealing with Resistance to Change".

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Speaking engagement topics: “Lean-Streaming Your Operations”, “Implementation Agents Wanted!”

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Highest Department of Defense Security Clearance: "Confidential" (Inactive)

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US Citizen / Current USA Passport