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Asheville, North Carolina, United States
November 05, 2018

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Jeff Callahan

Objective: To obtain a management level position within a people oriented company. Realize success through team problem solving and cooperation between functional areas.

Summary of skills: Lean Manufacturing, Lean Six Sigma, Leadership, ISO 9001 activities, Budgetary/Capital/Strategic Planning, Data driven to improve processes, 20 years of management experience

Professional Experience: February 2016 – Present iPlay, Inc.

Director –Distribution

Oversight of warehousing and distribution activities

January 1993 – February 2016 Arvato Entertainment (formerly Sonopress LLC) Weaverville NC

Director – Packaging/Warehouse/Distribution 2011- 2016

Budgetary responsibilities

oResponsible for multiple department budgets >$3M

Implemented distribution process (small scale)

oNon-automated solution due to customer relocation

oExecutive sponsor for new distribution customer (Project Management skills)

Facilitated cross-functional team to develop process

Warehouse improvements

oReduce costs – analyzing staffing requirements based on lean principles

oInventory management – proper FIFO of raw materials, implemented WIP process to minimize extra handling/storage of materials

oLean principles – reduction of waste through material flow

Director – Mastering/Replication/Printing 2002-2011

Implemented Lean manufacturing techniques (SMED/5s)

oFacilitated Kaizen events to improve efficiencies

Improved setup times in print department 30%

Improved turn time on molding tools by 50%

Improved productivity 10-20% year over year

Quality – Reduction of complaints from customers

oFocused on operator discipline for given procedures

Quality complaints from customers decreased every year

oImproved procedures to error proof (poka-yoke) processes

Oversight of 24/7 four shift operation (Quality/Operations)

Daily monitoring of key metrics driving Quality/Safety/Reliability/Productivity

Manager – Mastering Services 1993-2002

Startup operation

oHired/Trained operating staff

oDeveloped procedures (operating and safety, ISO)

oDeveloped metrics to monitor performance

oWorked in a cleanroom environment

Education: 1989 -1993 Cleveland Community College Shelby NC

A.A.S. Electronics Engineering Technology

Professional Development

2011 Champion Certificate (Lean Six Sigma)

2007 Villanova University (Lean Six Sigma Certificate of Achievement)

2004 – 2007 Bertelsmann University (Leadership Program)

Contact Information: Telephone (Home) 828-***-****

Telephone (Cell) 828-***-****

33 Willie Lane

Weaverville NC 28787

Email: mailto:


Peter Schaper – VP Operations – Arvato 828-***-****

Alisa Gantt – Distribution planner – Arvato 828--301-5225

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