Alan Frausto

Results-driven Operations and Industrial Engineering Leader with over 10 years of experience in the automotive industry. Expert in process optimization, Lean Manufacturing methodologies (7 Wastes, 5S, SMED, Kaizen, Kanban), and execution of cost-saving initiatives to maximize plant profitability and customer satisfaction. Proven track record in manufacturing layout design, line balancing, headcount control, and budget forecasting.

Strong expertise in managing supplier and OEM customer relations, executing process validations for launch programs, and navigating major customer portals.

Internal Logistic & Packaging Engineer - PUREM

(2023-01 - 2025-09)

• Developed and maintained packaging instructions for major automotive customers through internal systems and OEM portals, including Volkswagen, Audi, Ford, and DDC.
• Managed supplier packaging compliance and optimized materials to balance cost and quality standards.
• Designed ergonomic and efficient standard packs and packaging simulations utilizing Pack Assistant software.
• Monitored and controlled inventory levels for cardboard and returnable packaging (CHEP) based on production forecasts and consumption tracking.
• Optimized warehouse layouts, business yard flows, flow racks, dollies, and tugger routes to streamline raw material supply chains.
• Implemented visual aids and robust safety improvements across warehouse operations.
• Maintained master SAP data, updated POP/POF parameters, and reviewed CAPEX proposals for engineering projects.
• Designed customized flow rack configurations required for new incoming projects.
• Implemented a Kanban system for Work-In-Progress (WIP) production and returnable packaging, significantly streamlining floor workflows.
• Redesigned packaging architectures to increase freight volume utilization from 60% to 90%, generating $3,000 USD per month in savings.
• Optimized returnable packaging operations, achieving a cost reduction of $2,000 USD per week.
• Enhanced packaging materials to improve durability while saving $1,500 USD per month.
• Expanded warehouse storage capacity and improved overall space utilization through strategic layout engineering.

Manufacturing Engineer - Daimay

(2022-02 - 2022-09)

• Improved production layouts and structural workflows to enhance safety, quality, and productivity for current and launch programs.
• Performed comprehensive line balancing using Yamazumi charts to optimize SOP (Start of Production) and launch product lines.
• Implemented Poka-Yoke systems and Go/No-Go tools, drastically reducing assembly errors and operational scrap.
• Optimized material usage and Bill of Materials (BOM) structures to lower manufacturing costs and improve resource allocation.
• Led process validation (R@R) and qualification protocols for new launch programs, ensuring full compliance with automotive quality standards.
• Developed standard work instructions (WI) and conducted MRO material studies to streamline production processes.
• Supervised, coached, and mentored 3 manufacturing technicians, driving continuous improvement through Kaizen initiatives.
• Streamlined material usage and BOM management, reducing structural costs by $5,000 USD.
• Successfully designed and implemented a trimmed tool modification, achieving $8,000 USD in cost savings.
• Eliminated high-risk safety conditions on the production floor through targeted ergonomic and preventative engineering.

Industrial & Continuous Improvement Engineer - Motus Company

(2016-01 - 2022-12)

• Facilitated plant-wide Kaizen workshops and continuous improvement initiatives focusing on SMED, 5S, 7 Wastes, and Kanban.
• Designed lean production layouts, ergonomic workstations, flow racks, and fixtures to enhance safety, operator ergonomics, quality, and cycle efficiency.
• Tracked plant savings, controlled operational improvement metrics, and audited lines to eliminate non-value-added (NVA) activities.
• Conducted ergonomic risk analysis and redesigned workstation parameters to improve the operator "Golden Zone".
• Performed capacity studies on production lines, evaluating machine efficiency and headcount (HC) requirements.
• Applied time & motion studies, line balancing, and Yamazumi charts to improve productivity metrics (PPLH) and minimize scrap.
• Managed headcount control for both direct labor (DL) and indirect labor (IL), creating annual labor forecasting plans.
• Handled procurement engineering by creating purchase orders for specialized fixtures, facility materials, and production tools.
• Led plant-wide Kaizen initiatives (SMED, 5S, 7 Wastes) that generated $130,000 USD per month in savings, winning the Global Motus Kaizen Award.
• Rebalanced production lines and optimized machine capacity, allowing a headcount reduction of 8 operators and saving $84,000 USD.
• Implemented process improvements across regrind systems, roller machines, and packaging, achieving $71,000 USD in cost savings.
• Executed SMED methodologies on compression and injection molding machinery, reducing changeover times by 20 minutes.

Bachelor's Degree - Electronics Engineering - Instituto Tecnológico de Saltillo (2009-01 - 2014-12)