Manager Engineering

STEVE CARLSON

**** ***** *** ******, **** Alto, CA 94303

Home: 650-***-**** / Cell: 510-***-****

********@*******.***

Senior Manufacturing Operations Executive

EXECUTIVE PROFILE

o Senior manufacturing operations executive and advocate for lean manufacturing with extensive

success in optimizing cost with hands-on coaching and rigorous project planning methods. Highly skilled

team builder with collaboration across organizations, multi-national sites, supply chain partners, and global

outsource service partners (India-based engineering).

o Change agent and effective leader developing strategy and tactics toward continuous

improvement. Delivered exceptional business results in: engineering, quality, cost and time management

metrics. Leveraged uncommon breadth of functional management experience to drive change across

complex functional boundaries. Promoted continuous learning, personnel and team accountability,

coaching, training and certification. Directed plant closings and openings, acquisitions, and consolidations.

AREAS OF EXPERTISE

o Lean Manufacturing/ 5S / Kaizen o Certifications and compliance: ISO 9001, <

13485, 14001, RoHS

o Project and Program Management <

o Quality process improvement, goal alignment

o Functional leadership: Manufacturing,

and achievement

Engineering, Quality, Materials, Purchasing,

o Personnel and team development

Business Development

o Change management, Diversity inclusion o Positive morale

WORK EXPERIENCE

KIMBALL ELECTRONICS, FREMONT, CA 2008-CURRENT

GENERAL MANAGER

Recruited to improve operations in under-performing site for tier-2 contract manufacturing firm. Managed all

aspects of operations: Engineering, Production, Quality, Customer Operations, Purchasing, Materials,

Finance. Weakened market conditions prompting expected facility closure during consolidation.

Overall results: Increased inventory turns from 2 to 12+; Increased labor efficiencies from 50% to 112%;

Continuously reduced PPM defect levels to meet customers’ expectations; Maintained on-time delivery

performance at 99%; Championed multi-million dollar cost reduction initiative; Led certification efforts of ISO

14001 and expanded scope of ISO 13485.

Selected Achievements:

Strategic Planning • Coached management team on hoshin planning method; Organized 27

projects aimed at addressing 4 areas for strategic focus; recognized as best

practice in worldwide corporation

Personnel • Assessed personnel capabilities, performance and needs; Mentored

Development management team members to achieve critical performance requirements;

Recruited talent to fill organizational gaps

Lean Initiatives • Promoted culture of self-directed work teams; Introduced daily kaizen forum

and mentored teams’ continuous improvement work; Led plant-wide 5S

disciplined approach to managing work space, safety, and quality.

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CELERITY, INC. MILPITAS, CA 2006-2008

VICE PRESIDENT OF PROGRAM MANAGEMENT

Recruited to lead product development and projects for manufacturer of gas and liquid controls instruments

manufacturer. After 2 years, operations were downsized and sold to East Coast company.

Overall results: Designed and governed engineering management systems; Led operational efficiency

initiatives aimed at on-time delivery, quality, and cost improvement.

Selected Achievements:

PPM • Rolled out product portfolio management tool; Trimmed back more than 75

engineering projects backlogged within engineering organization of 100

engineers; Focused engineering efforts on critically important projects

Operations metrics • Led front-line process improvements, Identified causes of late deliveries,

established management reporting system, Reengineered business processes

and restored customer confidence

Quality system • Guided comprehensive quality improvement initiative to integrate supplier,

factory, field quality into a central data repository used to drive team-based,

problem solving efforts to meet company and customer performance goals.

NOVELLUS SYSTEMS.SAN JOSE, CA 2004-2006

DIRECTOR OF OPERATIONS ENGINEERING

Recruited to lead Manufacturing Engineering, Advanced Manufacturing, Configuration Engineering, Customer

Engineering Specials and Engineering Services for manufacturer of automation equipment for semiconductor

manufacturing industry.

Overall results: Led significant operational improvement efforts aimed at shortening product cycle times from

13 weeks to 7 weeks; Integrated engineering solutions into the order management process which resulted in

33% quality improvement and production operation consolidations.

Selected Achievements:

5S • Championed Lean Manufacturing / 5S initiative which resulted in closing

manufacturing facility which was sold for $4+M

Offshore • Selected, trained and fostered growth of offshore engineering team (from 0 to

engineering 100 engineers in less than 1 year); Improved engineering productivity and

product development that fueled sales growth; Standardized engineering

solutions for labor and time savings

Quality • Led cross-functional team improvement effort to increase accuracy of

incoming order configurations, utilizing web-based workflow methods, reduced

error rate by 80%.

CALIFORNIA TRAINING COOPERATIVE 2003-2004

LEAN MANUFACTURING CONSULTANT

Overall results: Advised clients on the implementation of lean manufacturing methodologies, building team

excellence; developed course materials for 40-hour Lean overview.

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ASYST TECHNOLOGIES.FREMONT, CA 2000-2002

VICE PRESIDENT OF MANUFACTURING

Recruited initially to lead M&A activities but re-assigned to lead multi-site manufacturing team struggling to

keep pace with high customer demand. After 2 years, the operations were wholly outsourced offshore.

Overall results: Directed manufacturing operations, facilities, security and safety for 4 domestic sites for $500M

manufacturer of automation equipment used in the semiconductor industry.

Selected Achievements:

Growth • Developed and implemented strategic plans to achieve key operational

metrics; led operations team of 600+ employees; Met performance goals while

doubling manufacturing output from $225M to $500M in one year

Quality • Drove structured quality improvement processes; Instituted closed-loop

corrective action system; Reduced workmanship defects by 75% over 6-month

period, achieved ISO 9001 certification.

JABIL CIRCUIT, SAN JOSE, CA 1998-2000

BUSINESS UNIT MANAGER

Recruited to lead business development efforts in a green field facility for tier-1 contract manufacturer.

Overall results: Directed business operations; Selected target customer accounts; Generated business plans

and proposals; Managed cross-functional teams for prototype and high-volume manufacturing of PCBA’s.

SOLECTRON.MILPITAS, CA 1995-1998

OPERATIONS MANAGER

Recruited to lead the management of Program Management for some of the tier-1 contract manufacturer’s

largest accounts; Later led manufacturing operations for system integration business.

Overall results: Directed operation of 500+ employees, responsible for operations metrics.

TREND PLASTICS.SAN JOSE, CA 1993-1994

MANUFACTURING OPERATIONS MANAGER

Recruited to lead manufacturing and engineering with 400+ employees for a large, privately held plastics

molding company

Overall results: Led ISO 9001 certification efforts; Reengineered manufacturing processes to drive out process

workmanship related defects; Through quality improvement efforts, able to save top 3 customer from exiting.

INTEVAC, ELECTRO OPTICAL SENSORS DIVISION.PALO ALTO, CA 1990-1993, 1994-1995

QUALITY MANAGER

Recruited by customer to direct quality, test, reliability and inspection of night vision products company.

Overall results: Served as TQM Chairman; Led development of strategic TQM initiatives related to training,

productivity, kaizen activities, suppliers, and SPC tools.

EDUCATION

MBA (Beta Gamma Sigma honorary society), SANTA CLARA UNIVERSITY, Santa Clara, CA 1988

MS in Mechanical Engineering, STANFORD UNIVERSITY, Stanford, CA 1983

BS in Mechanical Engineering, STANFORD UNIVERSITY, Stanford, CA 1982

Continuing Professional Training

• Franklin Covey: Great Leaders, 4 Disciplines of Execution, Priorities, Diversity

• Philip Crosby: Quality College, Train the Trainer

• Kaizens and 5S: NUMMI

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