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Manager Manufacturing

Location:
Pearland, Texas, United States
Posted:
October 08, 2016

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David R. Kelley

**** ******* ****** ********, ***** 77584

H (832) ***-**** C (469) ***-****

acwy2i@r.postjobfree.com

SUMMARY

A dedicated and results-oriented operations professional with extensive experience in quality control, production planning and scheduling, safety, inventory control, operations analysis, regulatory compliance, material and human resource planning, statistical process control, best practices, and supplier management in the manufacturing industry. A strong decision maker who trains and directs the activities of teams in the execution of production plans to meet organizational goals. Streamlines processes to increase profitability, improve cycle times, and maintain consistent product quality.

EXPERIENCE

BEBCO ENVIRONMENTAL CONTROLS CORPORATION, LaMarque, Texas

Production Manager 2016-present

Manage 15 direct labor employees in the production of custom air conditioners to be used in hazardous locations. Responsible for safety, quality, weekly ship schedules, shipping and the interviewing and selection of employees for my area.

Work with purchasing and engineering to ensure on-time delivery for all new products. Meet weekly to review quality, cost, resolve processing/delivery issues, and to prevent delays in fabrication and help to ensure on-time delivery to customers.

Developed tracking of employee’s labor hour’s vs planned time per job to help develop employee accountability for their job performance. This has resulted in improved job performance and reduction in cycle time.

Schedule the loading of the production area to balance the capacity of the manufacturing area to meet customer deliveries on time with product of high quality.

BENCHMARK ELECTROICS, Angleton, Texas

Manufacturing Supervisor 2012-2016

Supervise twenty five direct labor employees on two shifts for the stuffing and secondary’s area in a PCB assembly operation. Responsible for safety, line yield, weekly ship schedules, quality and the interviewing and selection of employee for my area.

Implemented a monthly training program for employees to improve cycle time and SPC controls for my areas of responsibility. Cycle time has been reduced by 20% over the last 6 months.

Implemented a 5S culture and Lean manufacturing for my areas of responsibility. Facilitated the value stream mapping for the secondaries area with the manufacturing team to improve work flow in the area and eliminate non value added operations.

Build a culture of team work between work groups to improve productivity and cycle time.

TEXAS INSTRUMENTS, Stafford, Texas

Automotive/Digital Signal Processor (DSP) Pre-Production Planner 2007-2012

Planned prototype devices from manufacturing of first samples to delivery of first part to customer. Worked with design, engineering, manufacturing, and marketing teams to deliver first samples and move device to full production release to meet customer requirements. Responsible for meeting all ISO 9000 requirements as verified by audits. Assumed planning responsibility for 19 new automotive devices, working with six program management teams to support major automotive custom customers and broad market catalog demand. Worked with all teams to develop and maintain sample delivery plans for engineering work and product qualification and delivery to customers

Released five programs (ten devices) on time to end customer to meet delivery schedules and financial plans for Texas Instruments.

Developed and implemented new device readiness checklist to ensure all items were in place to meet delivery plans for each product to allow device to move from samples into production successfully.

Implemented weekly/monthly update meeting with customers to review quality, sample delivery, and ramp to production plans on weekly/monthly basis. Improved communications with customer and internal teams to provide better understanding of needs and delivery dates. Addressed arising problems to provide opportunity to minimize impact of problems.

Implemented daily planning call with Dallas test floor to review material in process, set priorities, ensure material was started when received, and address process issues encountered on test floor. Coordinated meeting with all planners in DSP group, resulting in better communication between test floor and planners, improved cycle time, and fewer lost shipments.

TEXAS INSTRUMENTS, Dallas, Texas

KFAB Production Planner 2000-2007

Held responsibility for meeting KFAB planning group’s safety, quality, and production goals. Controlled factory inventory by monitoring wafer starts to remain in fabrication capacity. Planned and monitored all prototypes, production and development cycle time for management team. Worked with internal and external customers to meet delivery goals. Worked with internal business teams, vendors, and manufacturing teams to achieve low cycle time and acceptable yield for all new TI business designs. Responsible for meeting and maintaining records to meet internal and ISO 9000 requirements.

Maintained and managed all priority lots in KFAB and DBUMP to help minimize impact to overall cycle time to KFAB. Worked with internal and external customers to achieve desired business goals on key material in FAB within capacity of fabrication.

Planned and tracked all new device prototypes in KFAB to achieve 100% on-time delivery. Maintained flow charts on each lot and provided cycle time information to customers as needed to track each new and key lot to meet business objectives for each LBE. Planned and achieved first pass success on 25 of 25 new designs across multiple technology nodes, thus allowing TI to meet customer business plans and win new business and customers.

KFAB Planning Manager 1996-2000

Developed operation model for KFAB (wafer fabrication facility). Worked with all internal development groups to schedule and plan for manufacturing of new designs using pre-production roadmap. Planned for capacity by identifying bottlenecks ahead of production needs and requesting needed capacity. Controlled cost by monitoring use of materials and implementing pilot reduction program.

Worked with purchasing and photomask vendors to ensure on-time delivery for all new devices. Met weekly/monthly with vendors to review quality and cost, resolve processing/delivery issues, and help control cost for materials. Prevented delays in fabrication and helped to ensure on-time delivery to customers.

Interfaced with manufacturing team to control inventory and balance fabrication loading against capacity and constraints in fabrication. Maintained weekly/monthly starts spreadsheet used by fabrication and worldwide make team to determine future loading into KFAB and verify correct starts made in a balanced manner.

DP1/DM5 Manufacturing Superintendent 1994-1996

Held responsibility for start-up of new wafer fabrication facility. Coordinated hiring activities for both non-exempt and exempt supervisors, selection and ordering of new style clean room garments, drafting rules and policies, and training of all new employees in DP1/DM5. Coordinated with internal engineering teams to develop new technology manufacturing processes and flow for the next generation of products. Responsible for the manufacturing of new prototype designs in pre-production.

Worked with human resources representative in hiring of core group of manufacturing supervisors and direct labor employees. Developed and oversaw initial employee training at joint venture fabrication in Singapore, key in successful start-up of DP1/DM5 wafer fabrication for TI. Served as manager in country for three-week period of eight weeks spent in training in Singapore.

Collaborated with human resources in recruitment and hiring of second wave of exempt supervisors. Attended job fairs; screened all internal and external applicants to determine management team interview candidates for positions. Used video conferences with out-of-area applicants before bringing to Dallas for in-person interviews. Successfully hired 20 supervisors over six-month period.

Worked with training team to develop and implement job certification system for manufacturing specialists for use by supervisor and process engineering. Ensured all employees were qualified to run operations assigned; improved overall fabrication operations.

DLOG Manufacturing Superintendent 1992-1994

Oversaw 66 direct labor employees and two exempt supervisors in plasma/thin film in DLOGIC wafer fabrication. Held responsibility for 24/7 for meeting all production, cycle time, safety and process yield goals for area. Coordinated cross-functional teams to identify and develop action plans for correcting process yield issues. Performed ergonomic studies for job functions in the wafer-processing area.

Attended/certified to teach personal development classes for DDI. Taught class for all DLOGIC employees during fabrication upgrade down period. Taught classes which were key to success for new incoming employees for DP1DM5 on conflict resolution, cycle time, time management, and teamwork.

DLOG Manufacturing Coordinator 1989-1992

Supervised weekend coverage for DLOGIC and GEFE wafer fabrication area, manufacturing test floor, and photomask manufacturing area. Oversaw 118 direct labor and 20 supervisors reporting on weekends. Met all fabrication production, cycle time, safety, and process yield goals for areas on weekends.

DLOG Prototype Coordinator 1988-1989

Scheduled and tracked all prototypes in DLOGIC fabrication. Supervised staff of four indirect employees to provide 24/7 coverage for prototypes. Responsible for cycle time, yield, and reporting delivery schedules to internal customers. Presented weekly progress reports for upper management.

DLOG Manufacturing Supervisor 1986-1988

Supervised 20 direct labor employees in photo area of DLOGIC wafer fabrication. Responsible for second shift photolithography meeting all production goals, allocating resources, and ensuring all required maintenance on the equipment. Led monthly safety review of all incidents and discussion of monthly safety topics. Supervised 20 direct reports to meet all quality requirements and preparing for ISO audits.

ADDITIONAL EXPERIENCE

INTEL, Chandler, Arizona, Senior Production Supervisor, 1984-1986. Supervised ten direct labor employees responsible for processing of both four- and six-inch wafers in metal removal area in wafer fabrication. Used projection printers and steppers in photolithography process and etch area and wet and dry plasma etches for metal removal. Held responsibilities including safety, line yield, weekly ship schedules, and maintaining photomask library. Developed weekly tracking plan for all products required for week. Improved attainment of 90% to above 98% each week. Implemented use of computer to develop Pareto charts, allowing for identification of all rejects in graph format used to develop actions plans for area; fanned to all areas on all shifts improved process yield from 80% to 88%.

NATIONAL SEMICONDUCTOR, West Jordan, Utah, Senior Production Supervisor, 1983-1984. Served as supervisor of 15 direct labor employees in photolithography area in metal oxide semiconductor (MOS) front end, building both negative metal oxide semiconductor and complementary metal oxide semiconductor devices. Held responsibilities including maintaining balanced material flow and mix, wafer loss, cycle time, and utilization of labor.

TEXAS INSTRUMENTS, Dallas, Texas, Manufacturing Supervisor, 1979-1982. Supervised 26 direct labor employees in photolithography area in MOS wafer fabrication. Held responsibilities including forecasting monthly and daily run rates for area and maintaining balanced flow of material for photo lines. Performed weekly yield loss review: manual process of collecting weekly data. Wrote program for mainframe computer to collect information and summarized by device, number of wafers, reject reason, and date. Asked to develop and create program for all shifts and areas to aid supervisors and superintendents in managing yield loss, resulting in reduction of time to collect data and improved accuracy.

VALMAC INDUSTRIES, Nacogdoches, Texas, Quality Control Manager, 1978-1979. Served as quality control manager, ensuring all USDA regulations for poultry processing met. Held other responsibilities including monitoring process yield loss, ensuring accuracy of all shipments, and working with sales team to satisfy customer problems.

EDUCATION

STEPHEN F. AUSTIN STATE UNIVERSITY, Nacogdoches, Texas

B.S., Agriculture, Education, 1977

PROFESSIONAL DEVELOPMENT

DDI certified instructor in personal development, i.e., teamwork, conflict resolution, time management, 1990

Internal Texas Instruments training: SAP, ergonomics, 5S, MS Excel, 1990-2000.

Graduate seminary coursework, 1995-1998

COMPUTER SKILLS

Microsoft Office Products, SAP



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