Lester Sta Maria

NEW FACTORY SETUP

• Spearheaded the establishment of a new factory, overseeing all aspects from design to operation.
• Designed the manufacturing, testing, and warehouse facility layouts.
• Executed detailed electrical design for the Test Bay, incorporating the Test Stations, Remote Control Boxes, and Load Banks
• Collaborated with local authorities (MITI, MIDA, KASTAM) for necessary approvals and exemptions.
• Built the Production, Test Bay, Supply Chain, and Warehouse & Logistics departments from the ground up, including hiring, training, and process implementation.
• Developed a robust supplier base from scratch.

OPERATIONS DEPARTMENT

• Leading the Production, Testing, Warehouse & Logistics, and Supply Chain departments, ensuring safety, quality, timely delivery, and cost-efficiency.
• Collaborate with our HQ in Switzerland for process improvements and issue resolution.
• Manage the introduction of new models in the factory.
• Oversee component localisation and qualification of new vendors.
• Implement strategies for overall cost reduction of products.

QUALITY, HEALTH & SAFETY, and ENVIRONMENT

• Oversaw the QHSE of the company during the initial years of factory setup.
• Achieved ISO14001 certification for STATRON Malaysia.
• Conducted internal and external ISO audits.
• Successfully included STATRON in the Approved Vendor's List of several major customers.
• Participated in vendor audits by customers.

MISC

• Serve as the key user for the ERP software in STATRON (Microsoft Navision).
• Provide training and development for the operations department.
• Managed the setup and migration of the new HRMS system e-Leave, e-Claim, and e-Payroll.

PROJECT MASTER PLANNING

• Plan and manage the day-to-day production operation and ensuring that the customised UPS systems are assembled and delivered on time and in accordance to client's requirements, specifications and SOP, without compromising on product quality, safety and health.
• Oversee the creation and the maintenance of the project master planning, production detailed planning and the weekly shop-load reporting.

PRODUCTION MANAGEMENT

• Collaborate with various departments such as Supply Chain, R&D, Engineering and Testing departments to solve material, design and quality issues faced in production.
• Spearheading continuous improvement activities that uses lean methodologies and productivity tools to reduce line wastages and defects.
• Set up and monitor the yearly KPIs for up to 60 technicians and operators which are divided into 5 main production lines and 3 support teams.
• Train, support and drive the production department's Safety & Health, 5S, quality Improvement, and Training Teams in order to instill a safe, healthy and high performance working culture.
• Involve in the implementation and monitoring of the Schneider Production System (SPS) i.e. Schneider Electric's very own integrated socio-technical lean production system in the production processes.

• Led a team of technicians and operators in the Production department to assemble the Uninterruptable Power Supply (UPS) systems according to the design of the Project Engineers as well as according to internal work instructions and SOP.
• Oversaw the mechanical and electrical sections of the whole AC UPS assembly line and ensuring systems are produced on time and according to GUTOR's health and safety standards.
• Liaised with various departments as well as experts from the Swiss headquarters in solving technical issues.
• Ensured that all bulk materials in the assembly line are adequate for daily use and continuously implement Kaizen activities for line and process improvement.
• Production tools and equipment maintenance and control.

PROJECT MANAGEMENT

• Managed projects from the design stage, right through to production, testing and subsequently to the delivery of each UPS system, all the while providing frequent updates and reports to clients throughout the whole project cycle.

UPS DESIGN

• Responsible for the design of the UPS systems according to client's specifications and standards.
• Responsible for the preparation of the Bill-of-Material and the ordering of all required components as well as the preparation of all documentations requirement by the Production and Testing departments.
• Worked together with all relevant stakeholders in ensuring that the project is manufactured, tested and delivered on time and according to the requirements of the client.
• Liaised and coordinated with suppliers for the design and delivery of batteries, battery racks, battery accessories and special components.

• Managed the introduction of new Audio Visual (AV) equipment from the prototype right up to the mass production stage.
• Created and maintained assembly processes for the new AV equipment for each stage in the production cycle.
• Designed the assembly working instructions for the production operators with the aid of quality tools such as FMEA, Pokayoke (mistake-proofing) and motion time study.
• Lead the 'Shokiryudo' (ie. Initial Quality Assessment) team meetings with all related departments in order for the new model to proceed smoothly from prototype right up to mass production stage.