1. GONZALO VARILLAS
El Paso, Tx 915 208-4720. Cd Juarez 656 321- 3081 cel
gvarillaz@hotmail.com
PROFESSIONAL EXPERIENCE
JH Industrial 2010- Actual
Field Mgr. El Paso Tx/ Cd Juarez
Consulting and managing a variety of industrial projects for the SW region and sister plants along the border of Mexico-USA.
Molding Operations, Startups, Technical troubleshooting, Cost Reduction, Plastic Injection Molding training, Product development,
transferring of operations, process development and troubleshooting, root cause analysis, design validations, and many other projects.
Molding Engineering Manager Jan 2007- Jan 2010
INJEX INDUSTRIES (Toyota Tier 1) Hayward CA
Injex Industries is the largest supplier of interior trim to Toyota North America molding over 25,000 components/hour for the Tacoma,
Corolla, Matrix and other models for the Toyota plants in the continent. This is a disciplined operation that supplies Toyota based on a
well-structured JIT system and good teamwork.
 I managed the transition project of old to new models; developing strategic Engineering plans to achieve a smooth and flawless
transition without losing control of the production of actual models which I also improved the metrics at the same time as were;
scrap rate from 10% to avg. 3%, yield from 85% to 96%, downtime from 14% to 4% and on time delivery from 87% to 98%.
 Hands on worked and coordinated new mold designs and development with the R&D Dept. with integration of equipment, fixtures,
manufacturing systems and configuration of the production floor achieving the scheduled turn-around goals in 98%..
 With integration of a Kaizen team, we produced monthly costs reductions of avg. $185k utilizing world class tools with systemic
follow up, brain storming and team meetings for root cause analysis and permanent corrective actions.
 I managed all external vendors monitoring the production and maintenance of our tooling and fixtures with regular meetings in their
sites and measuring them by ranking their performance in quality, development per design and on time delivery.
 With the above improvements P&L turnaround was of +18% profit OA.
Operations Manager Jan 2007-Dec 2007
TYCO HEALTHCARE (Medical) Tijuana, Mexico
Tyco Tijuana is the most expensive and high technology operation of the Corporation with more than 2300 employees in one plant.
Tyco produces medical high products in the fields of Endomechanical Products , Energy Devices, Respiratory & Monitoring Products,
Soft Tissue Repair Products and Vascular Products
I managed the operations of Injection, Extrusion and rubber Molding, Thermoforming, Urology and Pouches using key leaning projects
to reduce cost and optimize overall performance.
 Improved yield from 88% to 95% in one month applying Lean projects on the floor.
 Cost savings of $175k in tooling repairs with root cause and effect analysis and permanent corrective actions in two months
 Customer complaints reduced by 25% with continuous improvement (Kaizen) and systemic follow up from team meetings for root
cause analysis and corrective actions applying Lean Manufacturing.
 Improved output in the Thermoforming operation from 900k to 1.4M units/day by refurbishing and optimizing key production
equipment.
 Successfully passed FDA audit with results of 95% compliance and one minor.
 Implemented certified Clean room maintenance and routine logged audits for continuous compliance.
Technical Manager (Automotive) Aug 2004-Jan 2007
Hi Stat (a Stoneridge Company) Juarez, Mexico
Hi Stat is the main automotive electronics division of the Stoneridge Corporation established in 1965. The main products produced are
most of the under hood and chassis sensors.
I Managed the new products development and operation transition and start up in a new plant. Sustained the implemented
manufacturing systems and improved them through kaizen (CI) over the daily activities of the operation.
 Managed the design and development of new products, molds & process for manufacturing of automotive speed, pressure,
temperature, and level sensors in Sarasota FL.
 I managed the design of all new machines and fixtures and their integration for the new ABS hall cell sensor and cable assembly
launching with up to 8 different lines/models of 25 stations each.
 Successfully transferred the new projects from Florida to Juarez Mexico coordinating the APQP for new product launching to first
“0” defect shipment to the customer. DV, PV, PFMEA, PPAP, DCP’s, are tools utilized during development of the programs.
 Analysis of P & L results and budget planning of the programs.
Molding Operations Manager Aug 1997-Jul 2004
Keytronic EMS Juarez, Mexico
Keytronic EMS Juarez is the largest operation of the Corporation producing 65% of its total profit with up to 3500 people. It is a
flexible consumer products producer which turns around a customer’s project from scratch design to full production in record lead
times. A large variety of products, assembly and loose, have been produced under its roof as are computer products, automotive,
consumer electronics, toys, household, and medical.
I was hired to turn around the molding operation into a profitable center. KEMS Molding represents the highest investment, operational
cost and the most profitable cost center of the plant. My main successful achievements for Keytronic EMS are:

2.  Responsible for the Molding Operations in a 70,000 sq ft with 60 molding machines 30 to 3000tn.
 In one fiscal Year (’02-’03), reduced cost of operation by 40% and PPM’s by 50%.
 Cost of outsources services reduced by 27% over previous year.
 CPK levels improved and maintained at 1.5+ on 90% of the products
 Reconfigured Molding Operation to receive 24 additional machines. This produced savings of $200k+ by doing it with internal resources
over outsourcing projected cost.
 As the Molding operation is independent from the manufacturing facility, my role was the one of a Plant Manager for having all the
departments in one plant.
 Quarterly meetings with Corporate Officers for analysis of Operation Budget and P & L. Molding because from being the worst loser to be
the most profitable cost center in the plant.
 Set up and launched an automated line for Microsoft with 12 robots and 6 molding machines.
 Set up and launched a 10 machines LIM operation and Thermoforming operation.
 Successfully transferred 9 new programs, being Lexmark the largest with 200 molds.
 Managed a new project for Little Tikes toys (New Hummer electric mountable) Designed and built new 9000sqft building to install a 3000 tn
machine to mold the main frame with a total investment of $1.8M.
 With the above improvements P&L turnaround was of +28% profit OA.
Headcount:
Crew of 350 in 4 shifts (24/7)
4- Sr Process Engrs, 1- Production Mgr, 1- Tool Shop Mgr, 1- Maintenance Supervisor, 12- shift Process Engineers, 8- Shift
Supervisors, 1- Tool crib Supervisor, 4- Planners, 44- Technicians.
 Processes: Injection molding, LIM (Liquid Injection Molding), Rubber molding, Insert molding, over molding, assembly, sub assembly,
automated assembly.
 Departments: 5000sqft tool shop operation with 400+ molds. 80% with hot runner system, 32 with core systems including pneumatic, stack
molds and 10 LIM tools.
 Maintenance Dept. Implemented and developed TPM and Predictive Maintenance. Designed and built a new tool crib.
 FAI (First Article Inspection) lab. For new mold qualification and internal tooling with PPAP and SPC on Mini Tab.
Molding Manager 1994-1997
BECKER GROUP INC. Brownsville, Texas
 Responsible for the Molding Operation of automotive trim for the 3 big ones with 32 Inj. Molding machines, 5 Brown Thermoforming
machines and secondary operations:
 Designed and developed 2 paint operations; one manual water base paint boot and one automatic wb & oil base paint boot with automated
conveying as well as implemented a maintenance program for it.
 Managed new programs and operations start up. (planning APQP, production, maintenance, tool room, process and QS quality system)
 Managed all tooling activities with 132 molds, 65 with hot runner system.
Maintenance/Tooling Supervisor 1990-1994
PRECISION ENGINEERING (PEC) El Paso, Texas
• Managed the molding plant startup (Planning, Transfer, Training and starting all equipment). Facilities, maintenance for
medical and automotive parts.
• Hands on, rebuilt 5 molding machines, mechanical, hydraulic systems and retrofit them from relay to AB closed loop logic
control system.
Molding/Maintenance Supervisor 1986-1990
BRK ELECTRONICS Juarez, Mex.
• Started up the new molding and thermoforming operations in Mexico’s facility.
Production Supervisor 1984-1986
COOPER INDUSTRIES Juarez, Mex.
• Research/development and started up the aeronautic sealed micro, mini switch and molding production lines for operations in
Mexico’s facility.
EDUCATION
BS degree Mechanical Engineer
Technical University (ITCJ)
BS Degree Industrial Engineer
University of Juarez (UACJ)
CERTIFIED TRAINING
Industrial Maintenance, Fluid power (Hydraulics) I - V, Electric Control & PLC´s, TPM/PM (Predictive Maintenance), P/DFMEA, DOE,
APQP, PPAP, SPC, Principles of 6 sigma, Project Management and Product Development, Industrial Electronics Technician, Plastics
Technology Upgrade, Auto Cad, Solid Works, Rapid design and prototyping, Close loop control, Scientific / Decoupled Molding, ISO 9000
Internal auditor, ISO/TS 164949:2000 Internal auditor, Lean Manufacture, Business Administration.
BILINGUAL; ENGLISH-SPANISH
(TRAINING RECORDS AND REFERENCES AVAILABLE UPON REQUEST)