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Manufacturing Lean

Escondido, California, United States
October 14, 2016

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Fred Eftekhari

Escondido, CA ***** 760-***-****

Operations Manager / Supervisor

Experienced and skilled in planning, problem solving, decision making, and follow-through, resulting in improved quality, equipment up-time, efficiency, safety, cost savings, meeting revenue, shipment deadline goals, and customer satisfaction.

Extensive and hands-on leadership experience spans 2 decades of supervision, management, and 1st-line management in Electronic devices; systems manufacturing; medical devices and implants; manufacturing engineering, and Lean manufacturing migration consultation with a group of diverse manufacturing companies. Successful and results-oriented leadership and management, engineering and Lean manufacturing consulting experience including:

Test First Line Management

Manufacturing Engineering Management

Manufacturing Management

3rd-shift Plant Operations Management

Equipment Maintenance Group Supervision

Surface Mount Area Supervision

Lean Operations Migration and CI Events

Customer Complaint and Failure Analysis

Assembly and Test Supervision & Management

Consulting in Lean Manufacturing & Kaizen Events in yield improvement and throughput

Operations Expertise

Manufactured products by design of methods and standards, priority establishment, and personnel supervision.

Established manufacturing quality standards, methods, facilities, policies and procedures by studying product requirements, engineering consultation and collaboration, and determination of equipment and facility budgets.

Established organization structure, recruiting, interviewing, selection, orientation and training of employees.

Achieved production objectives by establishing priorities, scheduling activities, monitoring progress, and problem resolution.

Promoted and pursued safety through engineering controls, procedural awareness, and ergonomics.

Achieved financial objectives by monitoring budgets and expenditures, analyzing variances, and initiating corrective actions.

Maintained staff results by recognition, awards, appraisals, performance planning and monitoring and disciplinary action.

Team contribution through collaboration with Quality, Engineering, Maintenance, and other related departments.

Technical knowledge to champion improvements in future product designs, processes, build and manufacturability.

Migrated and converted lines, cells, and processes employing lean manufacturing concepts and techniques to perform effectively and efficiently by engagement and inclusion of employees in lean and six sigma events, cause and effect and yield improvement.

Professional Experience

AIR PRODUCTS & CHEMICALS, Carlsbad, CA 2012 – 2016

Chemical Manufacturing Operations Supervisor

In a specialty cutting-edge high purity chemicals and custom container company which serves worldwide semiconductor industry, performing supervision and build management of a variety of custom Stainless Steel and Quartz vessels. Monitored multi-shift activities, performance, output and quality. Chaired daily production team meetings to address material, technical and process issues. Conducted lean and Six Sigma activities and projects to improve flow, 1st time pass yield, and throughput.

Led Sigma improvement projects by conducting FMEA and cause / effect analysis, resulting in leak test improvement of 10%.

Improved area layout and process flow, resulting in smoother flow with focus on safety and quality.

Championed changes to the container build process to use ergonomic tools such as adjustable stands, vises, and fixtures.

Led continuous Regular 6S activities and establishment of KanBan parts system at the point of use.

Independent Consulting, Lean Manufacturing Consultant 2005 – 2012

Consulted for companies in Defense, Aerospace, Medical device manufacturing, Food, and capital equipment manufacturers to setup lean manufacturing lines, cells, processes and areas. Organized 5S and Kaizen teams, improving layout, flow, and productivity.

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Independent Consulting (Continued)

Improved yield by performing Kaizen events and FMEA investigations to map processes and introduce improvements, provided training in work station organization and structure, team building and communication excellence.

Inclusion of existing work force and participation of team members to implement and champion changes which continued and endured after consultation.


Lead Manufacturing Supervisor / Foreman

Supervised manufacture of cellular and smart phones in a high volume manufacturing environment. Covered both the Surface Mount and Final Assembly / test areas. Accountable for personnel actions and allocation of shift resources to meet schedule in production of Qualcomm / Sony / Kyocera CDMA handsets. Oversaw other supervisors during night shift operations.

Organized 5S program to create a clean and organized factory.

Improved line layout and process flow, resulting in 60% higher output with less personnel.

Converted and established Lean manufacturing lines and work cells working with Sony and Qualcomm engineers.

I-BUS SYSTEMS, San Diego, CA 1994 – 1996

Manufacturing Manager

Managed Manufacturing Operations, Manufacturing Engineering, Assembly, Test, RMA, final assembly inspection, and custom assembly departments. Duties were new product release transitions to manufacturing, personnel and manpower actions, cost reductions, process setup, and making revenue and shipment goals.

ISO-9001 certification setup and renewal.

Comprehensive testing of CPU boards by Introduction of DESS, and B / I processes.

Redesigned and relocated plant facilities to new site.


Manufacturing Supervisor

Production Supervisor in a medium volume ASICS, HYBRIDS, and STANDARD products manufacturing company in charge of test, burn-in and posttest assembly areas. Managed output, productivity and all activities of multiple shift personnel in various areas to meet or exceed customer commitment dates and revenue goals.

Automated production test area by using handlers, resulting in double to triple throughput.

Reduced cycle time by 40% via linear loading, mix planning and set-up reductions.

Achieved 90% ship to customer commitments, resulting in CSI improvement of 30%.

UNISYS CORPORATION, San Diego, CA 1988 – 1991

Line Manager

Test center 1st line manager in semiconductor operations facility, testing BIPOLAR / CMOS single and multi-chip ASICS and pin grid arrays and probing wafers in an automated test environment.

Duties included communication of issues and problems to engineering, direction of shift personnel to allocate group resources for optimum efficiency and tester utilization, review of new test procedures, and monitoring accuracy of data base transactions.

Oversaw employee job performance evaluation, career development, and performance. Technically responsible for managing equipment problems and resultant down time, identification and communication of product problems to product engineering.

Designed and implemented improved methods, reducing cycle time by 40%.

Improved automation and data tracking, reducing labor cost by 20%.

Introduced standards and generated operating procedures to improve quality.

Cross-trained test personnel in departmental tasks, facilitating productivity and job satisfaction.

CTS CORPORATION, Irvine, CA 1986 – 1987


As managing supervisor of electrical testing department; environmental screening department; marking and serialization areas, and final assembly departments in a military hybrid manufacturing plant. Scheduled and coordinated technicians and operators to meet monthly shipment deadlines, as well as resolving technical and industrial problems. Performed hiring, performance reviews, growth and advancement planning of employees.

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Organized quality circles and team problem solving to exceed source inspector's requirements, resulting in rework reduction of 15%.

Implemented "Just in Time" program to consistently meet changing priorities and monthly shipment schedules.

AVX CORPORATION, Costa Mesa, CA 1982 – 1986

Supervisor / Test Engineer

Supervised test, assembly, and laser departments with no technical or management support. Directed and coordinated 3rd-shift test and assembly operators, utilizing resources with optimum efficiency in volume hybrid circuit manufacturing environment.

Designed hardware / software and test fixtures, analyzed hybrid circuits for performance and functionality. Debugged new designs and test correlation issues.

Technical Expertise

Microsoft Office Suite

MIL-STD 883C / 38510 and processes required to satisfy military procurement specifications; ISO cGMP, OSHA standards

Contributions and experience in compliance regulations

Automated test equipment such as Fairchild / Schlumberger Sentry 50, 1040, 20, 8; Advantest Takeda Riken test system, Electroglas 2001X and Pacific Western II wafer probers. Also familiar with Varian leak detectors, Benchmark furnaces and roller welders

HP Tektronix and Agilent measurement and testing equipment, and experience in programming IEEE-488 / RS232 compatible measurement and testing equipment

Manufacturing processes involving plastic molding, mechanical trimming and laser marking

Surface Mount (SMT) equipment by Panasonic and Phillips

Design of safe work areas, cells and benches as well as process safety, handling and processing of toxic chemicals which includes PPE designations such as respirators, specialty gloves and material handling tools and equipment


Bachelor of Science (BS), Electrical Engineering, Minor in Management Science, University of California, San Diego, CA

Professional Training

Managing People

Work flow loops and communication technology

Building Effective Supervisory Techniques

Sigma, FMEA, ACE problem solving approach

Effective Supervision

Statistical Process Control

Supervisor Academy

Lean Energizing

Lean Manufacturing concepts

Industrial Ergonomics

Accident Prevention and Predictive techniques

Just in Time" Planning, Manufacturing and Shipping Concepts

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