Tooling & Molding Engineering Consultant | Cost Reduction Expert
Cesar R. Flores
Plastic Injection Molding Expert Cesar R. Flores
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Specialists in Tooling & Molding Engineering, Operation & Molding Management
Cesar offers to reduce costs in Tooling & Molding Engineering, fixing, increasing productivity, and efficiency in the tooling and molding production floor through the elimination of non-value-added activities. He can reduce molding scraps by optimizing the Tool/Molding machine processing capability. Specialist in Product DFM and Tooling Design DFMM. Residing in Monterrey, Nuevo Leon Mexico. Leading associate for contacts in Mexico and Costa Rica. |
SUMMARY OF QUALIFICATIONS
PROFESSIONAL EXPERIENCE
Global-IMI, El Salto, JAL: Molding Plant Manager 7/2024 - 7/2025
Reporting to the NA General Manager, Responsible for managing 40 IMMs. Responsible for Engineering, reviewing math data, tool kick-off for Mold manufacture, molds ECRs, and Mold repairs. Managing 4 departments (Tooling Management, Molding Production, Processing, and Toolroom) with a total of 280 employees and all contractor suppliers.
Accomplishments:
Global Consultant Services, Tooling & Engineering-Toolshop Development 2/2022 - 7/2024
Micro Technologies, Coyol San Jose, Costa Rica
Development In-house State of State-of-the-art Toolshop, training collaborators to obtain Mold Maker Certification, changing the practices and dependencies of external Toolshops, increasing the competitiveness of Micro Tech, reducing dependency on
external suppliers, reducing delivery dates, increasing financial income, and reducing Headcount in the Toolshop Manufacturing Area. Optimizing and unifying the knowledge of the collaborators of the Advanced Engineering Department, and the knowledge of
Tooling & Molding Manufacturing.
Fleximatic S. A de C. V (ToolFlex). Director of Operations, JAL 1/2021 - 2/2022
Launching state-of-the-art Toolshop to reduce cost and time by farming out mold repairs and manufacturing, providing tool assessment in tools repair, refurbish, and quotation for mold manufacturing of 50 new tooling, helping to reduce headcount, and providing hands-on Training to current and new Toolmakers. Engineering Mold Making (Mold Design) & Shop Floor Management (CNC Milling and CNC EDM)
SRG Global, Business Unit Molding Manager, Irapuato, GTO 3/2019 - 11/2020
Report to the VP & General Manager, Responsible for managing 29 IMMs. review math data, tooling kick-off for Mold manufacture, molds ECRs, and Mold repairs. Managed 4 departments (Tooling Management, Molding Production, Processing and Toolroom, in total 180 employees and all contractor suppliers.
Accomplishments:
ZKW MX, Silao, GTO: Tooling-Molding Director 4/2016 - 2/2019
Reporting to the CEO/VP of Mexico, Responsible for launching 20 IMMs, Tooling & Molding Production, managed 4 areas (Tooling Management- Tooling Service, Molding, Metalizing in a total of 130 employees, Tooling Management), Toolroom New Products Engineering, and all contractor suppliers.
Accomplishments:
Monterrey: Tooling & Molding Consultant 1/2013 - 4/2016
Providing Tooling & Molding Support to diverse Automotive Companies located at the border.
Accomplishments:
Inteva, AMD, and other molding companies: reduced farming out mold repairs of 1400 Intricate molds, savings of $500K USD, and reduced mold repairs and lead time. Reduced the Tool shop Head count from 32 toolroom crew to 24 Toolroom crew with a saving of $300K USD per year.
Standard Tool & Die, Monterrey: Plant & Engineering Manager 3/2007 - 12/2012
Partnership with USA Headquarters, Managing Floor Operations/ Sales & Engineering. Added the Advanced Engineering area, 2 Tool Design Engineers, customer Liaison, and Tool shop Manager, Engineering Support of Know How to ensure mold manufacture and repairs were done on time and within Tolerances.
Accomplishments:
Progressive Moulded Products, Ontario Canada: Corporate Tooling Manager
11/2002 - 3/2007
Reporting to the Corporate Tooling Director, responsible for launching new Molding plant in Kansas City and McAllen, TX, together with Ford and GM programs, launched Ford Escape, Ford Flex, Mazda Tribute, and Malibu Console Assemblies, Tooling approval from Kick-Off to PPAP, and production released to the assembly line. Any task that I have been given, I have tackled with great success.
Accomplishments:
Cades Solutions, Waterdown ON: President/Engineering Manager 9/1981 - 11/2023
Manage & supervise +28 Experienced Toolmakers. Building and designing molds for connectors, electronics, under-hood, and High-Speed Injection Molding tools. Managed & supervised anywhere from 5-28 Top Notch Mold Makers. Manufacturing molds for Plastic Injection. Trained and reviewed employees based on their knowledge of manufacturing. Ability to design moulds, attend meetings with customers, prepare quotations, meet customers' goals, speed production schedules, and ensure that all objectives of the production floor are achieved. Trained on Machining-Mould Making-Mechanical workmanship standards and performed the daily review required, meeting production schedules. Assisting in Engineering prototype and first run jobs. Meeting customers’ goals while maintaining a high-quality product.
CERTIFICATIONS
Certification of Qualification of Master Mould Maker, Canada, Ontario
The Apprenticeship and Tradesmen’s Qualification Act ID 916954
SKILLS & TRAINING
- Proven track record of improving efficiency in Mold Makers, Machinists, Tooling Engineers, and Mold Techs' duties.
- Recognized ability of Managing Tooling-Molding, resins, and processing to reduce scrap to a standard of 1%
- Wide abroad hands-on experience in single, multiple cavities, for Medical, Automotive, and Electronics.
- Excellent problem-solving skills and focused on reducing scrap, headcount with Innovation.
- Proficiency in Product & Tooling DFMs, Mold Flow Analysis, and RFQ negotiations before Tool Kick-off.
- Risk Assessment of 3D native CAD Data review for Tooling kick-off to Tool Validation
- Reviewing project management and setting local KPI’s (cost, quality, scrap, OT).
- Technical Skills of Operating Toolroom machinery and software applications
- Certification of Master Mold Maker, Cad/Cam, and CNC Programming
- Molding Business Unit Operations, Tooling Engineering, and Tool-Room Management
- Bilingual (English Spanish) 100%
PROFESSIONAL EXPERIENCE
Global-IMI, El Salto, JAL: Molding Plant Manager 7/2024 - 7/2025
Reporting to the NA General Manager, Responsible for managing 40 IMMs. Responsible for Engineering, reviewing math data, tool kick-off for Mold manufacture, molds ECRs, and Mold repairs. Managing 4 departments (Tooling Management, Molding Production, Processing, and Toolroom) with a total of 280 employees and all contractor suppliers.
Accomplishments:
- Reduction of $350 USD HC from 380 to 280 in 8 weeks- Molding-(Poor Management and Leadership)
- Reduction of $400K USD Scrap from 18% to 3% in 8 Weeks- Mold & Tooling Issues (Poor Mold Maintenance and Molding Process)
Global Consultant Services, Tooling & Engineering-Toolshop Development 2/2022 - 7/2024
Micro Technologies, Coyol San Jose, Costa Rica
Development In-house State of State-of-the-art Toolshop, training collaborators to obtain Mold Maker Certification, changing the practices and dependencies of external Toolshops, increasing the competitiveness of Micro Tech, reducing dependency on
external suppliers, reducing delivery dates, increasing financial income, and reducing Headcount in the Toolshop Manufacturing Area. Optimizing and unifying the knowledge of the collaborators of the Advanced Engineering Department, and the knowledge of
Tooling & Molding Manufacturing.
- Improve the knowledge of Molding Engineering with Tooling and Project Engineers for New and Current molds in production.
- Reduction of HC from 48 toolmakers to 32- USD 200K- ToolShop-( Lack of Management and Leadership)
- Reduction of OTD and Quality 1stshot, increase capacity of mold delivery by 60% and 100% right at first shot. Increased sales $250K in 18 months- Improved Mold design, Tooling, Manufacturing, and Engineering.
Fleximatic S. A de C. V (ToolFlex). Director of Operations, JAL 1/2021 - 2/2022
Launching state-of-the-art Toolshop to reduce cost and time by farming out mold repairs and manufacturing, providing tool assessment in tools repair, refurbish, and quotation for mold manufacturing of 50 new tooling, helping to reduce headcount, and providing hands-on Training to current and new Toolmakers. Engineering Mold Making (Mold Design) & Shop Floor Management (CNC Milling and CNC EDM)
SRG Global, Business Unit Molding Manager, Irapuato, GTO 3/2019 - 11/2020
Report to the VP & General Manager, Responsible for managing 29 IMMs. review math data, tooling kick-off for Mold manufacture, molds ECRs, and Mold repairs. Managed 4 departments (Tooling Management, Molding Production, Processing and Toolroom, in total 180 employees and all contractor suppliers.
Accomplishments:
- Scrap reduction of USD 770K from 23% to 2.8% in 2.5 months- Molding-Chroming (Poor Drying of Resins)
- Scrap reduction of USD 400K 18% to 1.5% in 3 Weeks- Molding Chrome-Tooling Issues (Poor Venting)
- Scrap reduction of USD 200K 15% to 2.5% in 2 weeks- Molding Chrome- Wrong Screw (Resin degrading)
ZKW MX, Silao, GTO: Tooling-Molding Director 4/2016 - 2/2019
Reporting to the CEO/VP of Mexico, Responsible for launching 20 IMMs, Tooling & Molding Production, managed 4 areas (Tooling Management- Tooling Service, Molding, Metalizing in a total of 130 employees, Tooling Management), Toolroom New Products Engineering, and all contractor suppliers.
Accomplishments:
- Scrap reduction of USD 800K 95% to 3.1% in 6 months- Molding Lenses- Improved Screw and Drying (Resin degrading)
Monterrey: Tooling & Molding Consultant 1/2013 - 4/2016
Providing Tooling & Molding Support to diverse Automotive Companies located at the border.
Accomplishments:
Inteva, AMD, and other molding companies: reduced farming out mold repairs of 1400 Intricate molds, savings of $500K USD, and reduced mold repairs and lead time. Reduced the Tool shop Head count from 32 toolroom crew to 24 Toolroom crew with a saving of $300K USD per year.
- Improved Communication with the Tool shop supplier and sent tools to the USA.
- Improved capacity and production switching to 2K molding in 88 molds,
- Maximize the capacity of vertical molding and increase production with automatic molding.
- Reduced outsourcing mold repairs from 80% to 10%. Reduced the leading repair time by 50%
- Reduced scraps of USD 500K 37% to 3.2% in 5 weeks by managing Molding in Color- improving Cooling (under size) Savings of USD 600K by optimizing the cooling process, reducing cycle time from 118 secs to 58 Secs, Removed Headcount 50 operators grinding valve gates.
Standard Tool & Die, Monterrey: Plant & Engineering Manager 3/2007 - 12/2012
Partnership with USA Headquarters, Managing Floor Operations/ Sales & Engineering. Added the Advanced Engineering area, 2 Tool Design Engineers, customer Liaison, and Tool shop Manager, Engineering Support of Know How to ensure mold manufacture and repairs were done on time and within Tolerances.
Accomplishments:
- Scrap reduction of USD 800K 95% to 3.1% in 6 months- Molding Lenses- Improved Screw and Drying (Resin degrading)Savings of USD 500K, Reducing Headcount from 24 to 12 toolmakers by restructuring the tool shop and adding Advanced Engineering (3 Engineers-Design and Toolpath).
- Increasing sales from $400K to USD 1 million in 1.5 years by improving tool shop skills, providing Hands-on training
Progressive Moulded Products, Ontario Canada: Corporate Tooling Manager
11/2002 - 3/2007
Reporting to the Corporate Tooling Director, responsible for launching new Molding plant in Kansas City and McAllen, TX, together with Ford and GM programs, launched Ford Escape, Ford Flex, Mazda Tribute, and Malibu Console Assemblies, Tooling approval from Kick-Off to PPAP, and production released to the assembly line. Any task that I have been given, I have tackled with great success.
Accomplishments:
- Launching +450 molds of Ford Escape-Tribute, tools approved in first try-out for AAR and Production release.
- Saving cost of USD 600K after molds are released to production. 1500 ECRs were within target cost and on time by finding outsourcing toolshops to make all ECRs at customer cost and lead time approval.
- Developed PM program system and ECRs procedure.
Cades Solutions, Waterdown ON: President/Engineering Manager 9/1981 - 11/2023
Manage & supervise +28 Experienced Toolmakers. Building and designing molds for connectors, electronics, under-hood, and High-Speed Injection Molding tools. Managed & supervised anywhere from 5-28 Top Notch Mold Makers. Manufacturing molds for Plastic Injection. Trained and reviewed employees based on their knowledge of manufacturing. Ability to design moulds, attend meetings with customers, prepare quotations, meet customers' goals, speed production schedules, and ensure that all objectives of the production floor are achieved. Trained on Machining-Mould Making-Mechanical workmanship standards and performed the daily review required, meeting production schedules. Assisting in Engineering prototype and first run jobs. Meeting customers’ goals while maintaining a high-quality product.
CERTIFICATIONS
Certification of Qualification of Master Mould Maker, Canada, Ontario
The Apprenticeship and Tradesmen’s Qualification Act ID 916954
SKILLS & TRAINING
- Validating Production molds with the Scientific Method for single or multiple cavities
- Expert in launching new Tooling Program and Hands-on Mold repairs. (Fixing and Refurbishing)
- Safety Training: Lifting & Ergonomics
- Mold Flow, Cad/Cam Programming Certification
- Microsoft Office, Tooling RFQ Negotiation
- Tooling Program Management- North America, Central America, China & Europe.
- Lean Manufacturing Tools- JIT, SMED, Kanban, 5S, TPM, Right First Time, 7 Waste, PDCA.
- Core Tools- DFM, SPC, PPAP, FMEA. Cause Map
- Problem Solving Tools- 8D’s, DOE, 5W’s.
