Alexander Castillo

Experience

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  Autoridad de Carreteras y Transportación (ACT), DTOP

  Jan 2003 - Jan 2005

  Laboratory Assistant

  Responsibilities included:• Responsible for conducting tests for soils, aggregates, asphalt, and concrete materials such as sieve analysis of aggregates, absorption of aggregates, specific gravity of aggregates, liquid limit, LA abrasion, plastic limit and plasticity index of soils, and chloride penetration of concrete cores• Reporting procedures and results in accordance with the guidelines of Puerto Rico Highway and Transportation Authority to higher level engineers

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  Lagan Construction Group (Puerto Rico)

  Jan 2005 - Jan 2009

  Quality Assurance Technician

  Luis Muñoz Marín International Airport Project, Carolina, Puerto RicoThe 70 million dollar project consisted in the reconstruction and rehabilitation of an 8,000 (eight thousand) foot concrete runway and associated taxiways and connectors. Responsibilities included:• Supervising laboratory personnel and Quality Assurance• Coordinating, inspecting and reporting of all Quality Assurance testing to the client• Coordinating with Airport Operations and Airlines for construction activities• Producing concrete mix designs• Performing tests for concrete such as: Compressive Strength, Specific Gravity and Absorption• Earthwork soil testing and evaluation• Performing tests for soils such as: Liquid Limit, Modified Proctor, Plastic Limit and Plasticity Index, Specific Gravity, and Classification• Crushed aggregate base analyzing and testing• Performing tests for aggregates such as: Specific Gravity and Absorption, LA Abrasion, Sieve Analysis, Plastic Limit and Plasticity Index, and Fractured Faces• Sourcing and evaluating different quarry materials• Inspecting and reporting of field activities to ensure quality• Asphalt testing and reporting• Performing tests for Asphalt Pavement and Surface Treatment which included: Sieve Analysis of Extracted Aggregate, Specific Gravity and Absorption (Coarse and Fine) and Bulk Gravity• Usage of Nuclear Density Meter, and Stone CONE Equipment tests for density determination• Production of Laying Records for stone, concrete, and asphalt paving• Production of Quality Control documentation for monthly submittals of tests results for certification of works to higher level engineers• Submission of monthly certification with Project Quantity Surveyor and supplying Quality Assurance packages to higher level engineer for joint submittal• Overseeing and inspecting company Quality Assurance procedures for field works being performed Show less

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  Clondalkin Pharma & Healthcare Hull Ltd.

  Feb 2013 - Feb 2015

  Quality Assurance Inspector

  Responsibilities included:• Performing the sampling inspection as described in the procedure and notifying any discrepancy or out of specification results and documenting them following the Good Documentation Practices• Evaluating defects and classifying them accordingly to determine material disposition following the sampling plan established in the ANSI/ASQ-Z1.4 procedure• Verifying all the information related to the lot and assuring that it complies with all the requirements established in the product specifications and company procedures prior to shipment approval• Evaluating any discrepancy found as per company procedure in order to determine if it requires any investigation• Revising all “Job Jackets” prior to the lot final approval for shipment• Working in conjunction with the Shipping Department in verifying daily lots pending approval for shipment• Generating and verifying the Certificate of Compliance for final approval of lot for shipment• Maintaining control of all documents, including document development, approval, distribution and maintenance• Verifying all the information related to a lot’s final approval and assuring that it complies with all the requirements established in the product specification• Complying with the established procedures to assure that the materials are in compliance with the quality requirements and that all the documentation is completed accordingly to the Good Documentation Practices• Creating the shipping labels accordingly to the requirements in the packaging order• Performing sampling, inspection and notifying any discrepancy or out of specification results as well as determining any corrective actions as needed• Verifying the barcodes and “ID Matrix” and notifying of any non-conformances found and assuring that the equipment complies with the calibration requirements at the time of use, as applicable Show less

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  Essentra

  Feb 2015 - Mar 2018

  Responsibilities included:• Ensured adequate internal quality standards were in place and followed.• Determined quality improvement parameters by using statistical methods relevant to manufacturing processes.• Developed attribute and variable sampling plans, Acceptable Quality Limits (AQL), sequential sampling methods and acceptance criteria.• Maintained statistical process controls.• Analyzed data by completing hypothesis, normal distributions, and process capability analysis tests.• Prepared trend reports by collecting, analyzing, and summarizing data to define improvement plans.• Contributed to team efforts by accomplishing related results as needed.• Designed and implemented quality assurance systems consistent with industry standards that increased quality levels.• Served as primary trainer for all quality programs and initiatives.• Lead the problem-solving efforts for all quality complaints.• Oversaw the tracking and completion of defined corrective and preventive actions. Show less Responsibilities included:• Provided oversight of nine Quality Assurance staff.• Coordinated the work assignments and schedules of Quality Assurance staff.• Assisted in an acting capacity, in the absence of the Quality Assurance Manager.• Attended morning meetings and provided updates of Quality Assurance related activities.• Provided local training to the Quality Assurance staff related to cGMP’s and Standard Operating Procedures.• Provided technical assistance to other Essentra sites in the Quality Assurance area.• Identified and recognized the areas that showed strengths and established a plan of action for the areas that needed improvements.• Provided support to other areas of the facility (production, manufacturing).• All the responsibilities mentioned below in the Quality Assurance Auditor duties. Show less Responsibilities included:• Enforced the Quality System standard procedures and policies.• Audited manufacturing job orders and specifications for approval prior to starting the manufacturing process.• Responsible for ensuring finished product meets the established standards of quality including reliability, usability, and performance.• Analyzed quality data to identify trends and areas for improvement within the manufacturing and Quality System.• Ensured ongoing compliance with quality and industrial regulatory requirements.• Provided awareness to operators and supervisors of any quality issues.• Collected and inspected in-process production samples, manufacturing documentation and provided feedback of any concerns to departmental supervisors.• Reviewed defects with operators for acknowledgement and awareness.• Checked product for defects according to company quality standards and documented defects on the Quality Audit Forms.• Provided Quality Assurance (QA), Standard Operating Procedures (SOP) and Good Manufacturing Practices (GMP) training as appropriate and qualified all staff.• Followed all required safety procedures and use of Personal Protection Equipment (PPE).• Participated in the site validation program under the guidance of the Corporate Quality System Manager, assisting with the drafting of validation protocols and execution of approved protocols.• Performed thorough in process audits.• Managed the quality management system (QMS), documentation system, including document change control, review, approval, and issuance of system documents.• Managed planned procedural deviations according to local procedures.• Completed documentation for closing out job orders including label reconciliation, product monitor sheets, and ensure all necessary paperwork is within batch records and completed correctly.• Executed customers’ requests of press sheets, samples and any other customer requirements included with the production order. Show less

  • Quality Engineer

    Apr 2017 - Mar 2018

  • Quality Assurance Team Lead

    Apr 2017 - Jun 2017

  • Quality Assurance Auditor

    Feb 2015 - Apr 2017
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  Autajon Packaging USA (East Coast)

  Mar 2018 - Oct 2020

  Quality Supervisor

  Responsibilities included:• Assisted the Quality Manager in the day-to-day management of the QA department, enforcing quality control policies across the production processes.• Responsible for supervising and managing five Quality Assurance staff.• Coordinated and monitored sorting inspection activities to ensure the meeting of customer deadlines, productivity targets, and quality goals.Coordinated and facilitated the monthly quality meetings and attended the line management and new business technical meetings.• Supported the implementation and enforcement of the company’s Quality Plan.• Led investigations for customer complaints, returns or other related quality concerns.• Generated Certificates of Compliance (COC) for compliant finished goods prior to shipping orders to customers as required.• Created, approved, and administered color range books/standards/panoplies as quality control tools for manufacturing teams.• Generated bi-weekly waste and destruction reports for nonconforming materials.• Reviewed and reported quality status of production orders daily.• Ensured Chain of Custody requirements was maintained for all Forest Stewardship Council (FSC) related jobs.• Managed and assisted in an acting role as the Quality Manager in his absence.• Maintained a clean, orderly, and safe working area following 5S principles and eliminating safety hazards.• Monitored and evaluated the activities of the department employees, providing management, coaching, motivation, guidance, and on-the-job training as necessary to ensure operational, productivity, quality, and adherence to policies and procedures.• Organized work roles and responsibilities and allocated employees to achieve optimal efficiency to achieve department expectations and goals.• Tracked employee hours, unscheduled absences, and vacation schedules.• Effectively screened, interviewed, and short-listed individuals for open positions within the department. Show less

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  MM Packaging

  Oct 2020 - May 2023

  Quality Manager

  • Managed the Quality Assurance department of a $30MM folding carton packaging business for the pharmaceutical and medical device sector.• Contributed to a 30% reduction of Cost of Poor Quality (COPQ) resulting in an average yearly savings of $100M and an overall 40% reduction of customer complaints.• Responsible for managing a team of fifteen quality assurance staff.• Supported the effective delivery of internal audits and ensured compliance with standard requirements in design and manufacturing processes e.g., Good Manufacturing Practices (GMP), ISO9001, PS9000, Forest Stewardship Council (FSC). In addition to company policies and strategic objectives.• Managed the calibration program including the maintenance of the equipment calibration list, the management ofcalibrations and their frequency.• Facilitated the Change Control process at site level ensuring a successful outcome, including raising and approving change requests, completing change impact assessments, tracking, monitoring, and reporting on change progress.• Facilitated, reviewed, and approved deviation investigations Root Cause Analysis (RCA) conducted at site level for both internal and external deviations including the systematic capturing and implementation of Corrective and Preventive Actions (CAPA).• Reviewed, assessed, and qualified suppliers. Show less