Rafael F. Tonin
Manufacturing Process Engineer @ Caterpillar Brasil Ltda.
About
● Professional graduate in Automation and Control Engineering, fluent in English, with over 20 years of experience in the field, working in large national companies, with a focus on manufacturing, assembly, painting, quality control, safety, project development and governance, additive manufacturing, Industry 4.0, and advanced automation systems. ● Expertise in leadership and project management with Six Sigma (over 3 years), focusing on process improvements, operational efficiency, and measurable results. Experience in training and mentoring teams, spreading the culture of continuous improvement and operational excellence. ● Solid experience in developing new products and services, aligning innovation strategies with market needs and corporate goals. ● Strong experience in market trend analysis, identifying opportunities for innovation, and coordinating Research and Development (R&D) initiatives, providing sustainable and competitive solutions. ● Skilled in utilizing advanced data analysis tools and KPI management, ensuring maximum productivity and meeting established goals and deadlines. ● Extensive knowledge in preparing management reports, monitoring performance indicators, and providing insights for strategic decision-making, contributing to the effectiveness of business processes. ● Highly skilled professional in working with multidisciplinary teams, dedicated to duties, results-oriented, and focused on resource optimization. Organized, responsible, flexible, and with strong adaptability and leadership skills. Keywords: Engineering, automation, control, continuous improvement, process management, project management, Six Sigma, lean manufacturing, data analysis, operational efficiency, cost reduction, innovation, product development, research and development, process optimization, team leadership, performance indicators, resource management, prototyping, product design, market strategies, solution development, critical thinking, results management, organizational culture, trend analysis, strategic planning, quality control, productivity, training and mentoring, risk management, process integration, productive efficiency, KPI monitoring.
Brazil
Piracicaba
Information Technology & Services
Teamcenter, Realização de testes, Design de produtos, CAD, Equipamentos rotativos, Entrega de projetos, Engenharia de produto, Comunicação oral, Controle de qualidade, Processos da qualidade, Gestão Lean, Ações corretivas, Treinamento, Negociação, Inglês, Habilidades de supervisão, Office 365, Kanban, monitoramento de KPIs, eficiência produtiva
Experience

Manufacturing Process Engineer
Piracicaba, São Paulo, Brazil
● Developing and improving assembly processes, aiming to maximize efficiency, reduce operational costs, and enhance the final product quality. ● Technically and strategically resolving recurring issues on the production line, seeking innovative solutions to maintain operations and ensure continuous improvement of processes. ● Implementing quality control systems and ensuring compliance with safety and quality standards, always focusing on excellence in results. ● Applying Lean Manufacturing principles to optimize workflows and eliminate waste, generating high productivity without compromising quality. ● Fully collaborating with interdisciplinary teams during the design and production phases, actively contributing to the improvement of manufacturing methods and product designs to meet market and quality needs. ● Facilitating continuous training for production teams to ensure they stay updated on new processes and methodologies, maintaining an efficient and motivated work environment. Main results: (1) PFMEA Governance (Field Failures) – Risk management and elimination of 100% of delays, ensuring better monitoring of opportunities. (2) Efficiency Improvement Project (Subassembly - C FRAME - MTP) – Balancing the times for all models, resulting in a 15% increase in efficiency. Eliminating high-energy risks in human/machine interaction by modifying the layout, making the process safer.

Six Sigma Black Belt Program Manager
● Strategically communicating progress and results of initiatives to stakeholders at all hierarchical levels, ensuring transparency and alignment between projects and business objectives. ● Leading the execution of Six Sigma projects from inception to implementation, focusing on delivering results aligned with the organization’s strategic goals and having a direct impact on continuous process improvement. ● Advanced use of statistical methodologies for diagnosing issues, identifying root causes, and creating data-driven solutions that promote significant efficiency gains. ● Responsible for training and mentoring Green Belts and employees in Six Sigma concepts, fostering the adoption of a culture of process excellence across the organization. ● Continuously monitoring performance through key performance indicators (KPIs), enabling efficient tracking of the effectiveness of implementations and operational adjustments needed to achieve organizational objectives. ● Effectively coordinating resources, budget, and project scope, ensuring all phases are completed within established parameters for time, quality, and cost. Main results: (1) Cost Reduction at the Effluent Treatment Plant – Savings of 13%, totaling R$ 217,533.00. (2) Improvement of OEE at the RIW Painting Line – Increased OEE from 66% to 80%, establishing a foundation for future improvements with a goal of 85%. (3) Review of CBL Transfer Pricing – Implementation of a new model resulting in a cost reduction of R$ 139 million.

Manufacturing Process Engineer
Piracicaba, Brasil
● Developing and improving manufacturing processes to maximize efficiency, reduce operational costs, and enhance product quality. ● Strategically and technically resolving recurring issues on the production line, seeking innovative solutions to maintain operations and drive continuous process improvements. ● Implementing quality control systems and ensuring compliance with safety and quality standards, always with a focus on excellence in results. ● Applying Lean Manufacturing principles to optimize workflows and eliminate waste, achieving high productivity without compromising quality. ● Fully collaborating with interdisciplinary teams during the design and production phases, actively participating in improving manufacturing methods and product designs to meet market and quality needs. ● Facilitating continuous training for production teams to ensure they are updated on new processes and methodologies, ensuring an efficient and motivated work environment. Main results: (1) Revitalization of the PFMEA Tool – Led the process structuring, team training, and standardization, enabling preventive actions on both new and current processes, reducing rework and quality issues. (2) Implementation of the FUSION NPI Program – Strategic analysis of installed capacity, investments, weldability, and safety/ergonomics risks, contributing to product adjustments, eliminating 8 critical safety risks, 2 ergonomic risks, and 100% of welding interference. (3) Re-manufacturing of the HEX Chassis in Mexico – Developed welding procedures, process qualification, and provided customer support. This action avoided R$ 350,000.00 in warranty payments to Caterpillar Piracicaba.

Research and Development Consultant | Strategic Planning
SPARKY - INDÚSTRIA E COMÉCIO LTDA
Piracicaba, São Paulo, Brasil
● Defining long-term goals and strategic direction for the company, based on detailed market analysis and identification of innovation areas with high growth potential. ● Developing new strategies that boosted innovation initiatives, coordinating the creation of new products, services, and technologies in alignment with market needs and future trends. ● Leading R&D projects, overseeing all phases of design, prototyping, and testing, ensuring a continuous flow of new solutions for the company and its clients. ● Leading a multidisciplinary team of specialists, fostering creativity and generating innovative ideas while maintaining focus on project goals and timelines. ● Managing strategic partnerships and providing expert advice to both internal and external clients, promoting innovation as a competitive market differentiator. ● Coordinating marketing and sales activities related to new products and innovative solutions, optimizing the integration between R&D and market areas. ● Monitoring innovation KPIs, ensuring that projects remained within financial and schedule parameters, promoting efficient resource management for innovation. Main results: (1) UV Light Sterilization for Environments – Developed radio-controlled robots and air sterilizers, with prototyping and laboratory validation, ensuring the elimination of germs and bacteria with 99.99% efficiency. (2) Redesign of Filtration Equipment in the Tire Line – Identified opportunities for compliance with NR 13, resulting in the redesign of the equipment according to current regulations, ensuring safe and flawless operation. (3) Automation of Pressing Process – Provided consultancy and implemented an automated solution for a high-risk manual process, using a machine with a coordinated table and automatic pressing. Eliminated safety risks, quality issues, and maintained operational uptime.
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