Constantin Stoica

Areas Constantin Stoica is Knowledgeable in:

Techniques Constantin Stoica Uses:

Constantin Stoica's Problem Solving Skills:

1. Layout optimization, material flow
2. EV, Hybrid, Hydrogen Cells
3. APQP, PPAP, Process Flow, FMEA, Control Plan
4. Automatics
5. Supply Chain Management
6. Data Analysis & Visualisation
7. Standardized Work, Visual Management, Accountability
8. Manufacturing Processes - Heat Treatments, Injection Moulding, Painting, Assembly, Machining, Fabrication
9. Design for Manufacturing, Value Analysis Value Engineering
10. Strategy, Policy Deployment
11. Lean Manufacturing, Operational Excellence, Continuous Improvement - deep knowledge
12. Problem Solving - A3, 8D, 6Sigma, Ishikawa, 5why, mind-mapping, DOE, MSA, Pareto, brainstorming, etc
13. Powders Metallurgy
14. Cost Benefit Analysis, P&L, Budget
15. Autocad, Solid Works, Office Pack
16. Innovation
17. Operations Management
18. Manufacturing Engineering
19. Maintenance & Facilities
20. Out of the box thinking, creative problem solving
21. Project Management

Constantin Stoica's Problem Solving Experience:

1. - Magna - Improved JIS (Just-In-Sequence) BMW MINI assembly line after leading a project which reduced the walking and occupied area with ~26% and the headcount with 8%. Implemented standardized work, team concept and visual management. Obtained BMW buy-in, involvement and recognition for improved quality.
   - Turned around paint line (automatic line, 12 robots, ~3000 sqm) performance after leading a 2 months’ taskforce. Right First Time – 25% improvement; Scrap – 50% improvement. Directly in charge of application, paint preparation and maintenance in this period;
   - Conducted 120 RIEs (Rapid Improvement Events = Kaizens) involving ~ 80% of the workforce & coordinated 4 6Sigma Projects
2. - Won an internal Innovation contest after a 1 week workshop in Germany in Feb 2013. Our project was named "The Flying Car" and combined EV, Fuel Cell, ADAS, modularity, self-sustainability features
3. - Defined and Implemented a solvent reclaiming/recycling solution across multiple Magna facilities with paintlines. The solution consisted of an automatic load/unload ATEX solvent distillation unit which used a diathermic oil and was able to recover the solvent used to flush the paint circuits, without losing its properties and making it infinitely reusable. The recovery efficiency was ~70% and the savings were millions. The environmental/regulatory implications were a big benefit as well.
4. Pirelli Eco Technology:
   - Innovation: DOE (Design Of Experiments) programs studying composition, sintering behavior, additives (special materials: Boron Carbide), thermal treatment profiles resulting in substantial quality, productivity and cost improvements: 100% throughput increase (double-deck system, speed increase and temperature profile optimization); 50% scrap reduction; 10% electric energy consumption reduction; 15% Argon consumption reduction; 27% Nitrogen consumption reduction;
   - Innovation: Started the in-house capability for manufacturing Kanthal heating elements for Pre-Sintering & Oxidation furnaces which reduced the maintenance costs by >10%;
5. Magna
   - Transferred the full production (injection moulding, painting & assembly) of the Tailgate Handle for Ford Focus C346 from Germany to Romania (~80000 units/year) within time and budget. The launch was flawless while quality and customer relation were improved.
   - Transferred the full production (injection moulding & painting) of the Front/Rear Bumpers for VW Golf 6 spare parts from Czech Republic to Romania (~70000 units/year) within time and budget constraints;
   - Increased with 30% in 6 months the MAFACT assessment score (measuring worldwide lean implementation in Magna plants) for Magna Banbury and obtained 2nd best of Magna Exteriors Europe MAFACT assessment score for Magna Romania;
   - Achieved >4% of sales cost savings from operational improvement projects;
6. - Achieved >5% of sales cost savings from operational improvement projects; Obtained 2nd and 3rd place at the annual Eaton Aerospace world-wide Continuous Improvement Awards; Defined strategy and roadmap to achieve Model Plant Status.
7. ADL (Alexander-Dennis Limited) UK
   Defined the World Class Manufacturing Strategy & Roadmap, business processes map and “KPIs tree” (goals deployment);
   Drove 6 NPIs (New Product Introductions) concerning new bus and coach chassis concepts, high complexity, high mix and low volume within a 1-year timeframe;
   Completed a DFM (Design For Manufacturing)/VA-VE (Value Analysis/Value Engineering) program with savings of >10% of the production cost for single deck 2 & 3 axis Diesel bus chassis
   Completed the Standardized Work Program achieving 30% build hours reduction and 50% improved quality across 3 product families (single deck 2 & 3 axis Diesel bus chassis, double deck 2 axis Diesel and hybrid bus chassis & double deck 3 axis Diesel bus chassis)