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Engineer Quality

Chino Hills, CA
April 21, 2020

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Sam Irani

**** ***** *******

Newport Beach, CA *2660



A position that benefits from my knowledge and engineering skills, plus methodical and leadership approach to productivity improvement.


• BS in Industrial Engineer

Major Field: Industrial Production

• Lean Six Sigma – Black Belt Certified from Villanova University - May 2014

• California Certified EIT

• MS in Computer Science - California State University of Fullerton – May 2018


More than ten years of ongoing continues improvement expertise with unique background combining production management and industrial engineering in world class high speed and volume manufacturing field. Proactive, performance-driven professional with expertise in leadership and problem solving, and startup operations. Keen understanding of business priorities.

• Operation Management • Risk Management • TPM & HPO

• Project Management • Resource Management • RCA (Root Cause and Analysis)

• Kaizen • JIT (Just-In-Time) • Capital Project Management

• Six Sigma Lean • SPC (Statistical Process Control) • SMED / Center-lining

• 5s • FMEA (Failure Mode & Effective Analysis)


Hydro (Aluminum Extrusion Industry) City of Industry, CA

Continuous Improvement Manager April 2019 – April 2020

Responsible for managing all Continuous Improvement Projects through facility.

Coached and trained Managers and Supervisors to use Guiding Principles of Lean manufacturing.

Standardize process of aluminum extrusion in order to reduce defective items from 5.6% to 0.8%.

Improve production rate of extrusion and increase efficiency by optimizing recipes of production by 18%.

Implementing 5S through work stations and warehouse.

Eliminate repetitive quality issues by finding root causes and redesign production method in some cases.

WNA (Plastic Injection Mold Industry) City of Industry, CA

Continuous Improvement Engineer December 2017–March 2019

Responsible for managing all Continuous Improvement Projects through facility.

Coached and trained Managers and Supervisors to use Guiding Principles of Lean manufacturing.

Provided training for Managers, Engineers, Supervisors, and Technicians on problem-solving tools such as DMAIC, PDCA, Ishikawa diagrams, and Five-Why’s.

Manage all Automation Projects which needs capital investment of more than $200K.

NBTY Inc. (Dietary & Nutrition Supplement) Garden Grove, CA

Operational Excellence Leader March 2010 - May 2017

Responsible for analyzing manufacturing process and implementing Six Sigma Lean projects.

Calculating OEE and other KPI’s (Creating user friendly Data Collection and Visual Management System).

Joined safety community as a leader and reduced recordable incident annually.

Conducted time studies and established standard work operations in a Lean and Kaizen manufacturing discipline.

Teach the concepts of Value Added vs. Non-Value Added; empowered site associates promoting wastes elimination principles. Facilitator of Op-Ex tools, which are based on the teachings of LEAN Manufacturing, TPM, TQM, Six Sigma, and High Performance Organization.

Lead CAPEX, ROI engineering short and long term projects with FMEA (failure mode effects analysis).

Key Accomplishments

Modified production lines layout in order to reduce production cost by 42%.

Increased production rate by 27% with some line modifications.

Used DMAIC tool to reduce documentation errors in manufacturing facility by 34%.

Applied VSM (Value Stream Mapping) to reduce lead time of some products by 18%.

Implement TPM tools and improve OEE from 54% to 72%.

Facilitate and changing management leadership skills through entire plant.

Using SPC and Minitab software in order to reduce defective items and improve Quality by 6%.

Reduced TIR from 4.3 to less than 1 by implementing 5S and boost safety program.

Reduced rework items by adding some instruments in line.

Reduced changeover time by 50% (about 180 changeovers monthly).

Increasing efficiency of all production lines by eliminating or reducing tops downtime in each line.

Improved Preventive Maintenance Downtime program and reduce Maintenance Breakdown by 5%.

Managed improvement projects that resulted in over than $5 MM in cost savings in 2015.

Alacer Corp. (Dietary & Nutrition Supplement) Foothill Ranch, CA

Quality Engineer October 2006- March 2010

Responsible for controlling quality of products, raw materials, and process.

Designed FMEA(Failure Mode and Effective Analysis)

Applied SPC (Statistical Process Control) to control Quality.

Increased customer satisfaction by improving quality of products

Key Accomplishments

Reduced defective items by 5% due to apply SPC.

Increased customer satisfaction by 3%.

Modified some SOPs in order to increase efficiency of process.


Microsoft Office (Word, Excel)

Microsoft Project


Familiar with ISO and MRP (Manufacturing Resource Planning)

Six Sigma Lean

Continues Improvement Strategy

ERP (Enterprise Resource Planning)

SQL database analysis

High Performance Organization (HPO)

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