Senior Lean Process Engineer and Consultant

Fred Vahdati **********@*****.*** US Citizen

**** ******** ***. ***

Santa Monica, CA 90404

Cell 310-***-****

Career Objective:

Skills:

Consultant

Boeing -Product Lifecycle Process Engineer

Boeing Airplane Level Engineering Integration (ALEI)-System Engineering

SAS Interior Modules

Electric Car

Attaining Senior Product Manager position impacts employer’s bottom line utilizing my education and experience in Lead Industrial Engineer Team, Lean+ facilitation, Assembly / Manufacturing Process, Problem Solving / Product Defect, Facility Design, Capacity Planning, ERP/SAP/MES, Cost and Process Improvement to motivate diverse teams to be successful and empowered to accomplish their task and support customers.

Manufacturing / Lean: Six Sigma Blackbelt, Cost reduction & Profitability, RCCA, Theory Constraint (TOC)/PNET), Factory Optimization, Data Analysis/ Analytical, VSM, Production Flow Design, Routing, Production Preparation Process (3P), Manufacturing Execution System (MES), Manufacturing (Aircraft, PCB, electronic, Satellite, wires, assembly & test), Safety (EHS), 5S, FOD, A3, Capacity Planning, Jira

Supply Chain: MRP/ERP, Logistics (3PL), customer/ supplier interface, Demand Management, Forecast Scheduling, SIOP, Kanban, SAP (PP, MM, PM), Product Tears down, Inventory Management, cost modeling.

Quality: SPC, Sampling, Quality Management System (QMS), AS9100, Statistical Product Acceptance Requirements (AS9138), Auditing experience, Quality Optimization, Quality Data Analysis & Tacking, APQP, GD&T, Boeing Problem Solving Model (BPSM), Resolved Product Defect.

Manage Process Improvement / Lean Manufacturing Integration 2/2025-now

Promoted continuous improvement and problem-solving culture using data.

Coaching facilitation of process improvement workshop.

Leading, facilitating, and project improvement workshop.

Implemented lean+ & Method Analysis utilized SIPOCs in manufacturing and business processes.

Level 5- Sr. Process Engineer- Supply Chain Engineering (SCE)

4/2024- 2/2025

Led supplier quality team to identify numbers of specifications with Statistical Process Control (SPC)/ Six Sigma Black Belt & Initial Reliability Requirements (IRR) and provided solutions to the supplier.

Led supplier Notice of Escape (NOE) reduction & Root Cause Corrective Action (RCCA) project caused by impact BCA Engineering serialized Production Revision Record (PRR) changes. Utilized SIPOCs for supplier NOE process.

Led and support Supply Chain Engineering (SCE) initiative to link the ERP supplier commitment date to the MRP to monitor supplier delivery progress.

Provided technical solutions for the supplier manufacturing process.

Level 5- Sr. Project Engineer /Program Integration Mgmt. 2/2022-

04/2024

Led N21-41 FAA Fuel system for all BCA & managed IPT to ID parts w/o bond path in the tank for all BCA programs. Resulted report to FAA.

Project Management Led- 24 technical engineer 7 programs IPT

Led RCCA of Bonding and Grounding process,

Used AI CHATGPT to evaluate Bonding / Grounding data & location inside AP.

Coordinated activities, budgeting, & managed the technical team in Boeing India.

Led, facilitate lean+ workshop & APQP “standard work” team

Director of Industrial Engineering 12/2020-

07/2021

Manage 2 Sr. Managers, 5 IE, and 15 Mechanics

Designed and budgeting high speed automated lane w/ robots.

Performed advanced Industrial Engineering & efficiency analysis of production.

Boeing 767 Program

Profitability

Boeing 787 Program

Profitability-Composite, Cabin & Galley

Boeing 777 Program

BPS Manager

System Installation

Boeing BDS

C130AMP Modification Program

Thales IFE

VACCO Industries-Space & Satellite Program

Allied Signal (Currently Honeywell)

Engine & System

Dean / US Range

Food Equipment

Level 5-Sr. Lean Process Engineer, Enterprise Program Mgmt.

Facilitated Lean+ VSM workshop to increase production build in 767 programs.

Developed SIPOCs & analyzed supply chain process used AI to forecast production demand data.

Performed Bill of Material (BOM) analysis.

Applied product Teardown to obtain parts should cost.

Scrum leader of 767 System Installation Rapid Response Time (RRT).

Developed Industrial Engineering plan and facilitated lean+ VSM workshop. ID opportunities $500 hours saving & flow days.

Led RCCA for AR fuel to avoid test failure.

Resolved the supply chain 2nd issue and supplier delivery.

Led team implemented Precedence Network (PNET) in 767 System Installation to reduce flow days, remove constraints, bottleneck & run efficiently.

Used Pro Model simulation & analyzed Capacity Planning.

Level 5-Lean Global Production & System leader

Scrum master for 787 interior builds and managed 7 people.

Led quality team for Quality Data Analysis & Auditing of builds process using AS9100 and RCCA.

Implemented inspection optimization to reduce unnecessary inspection and use AS9100 audit saved over 200 hours.

Led 5 engineers & 10 mechanics using PNET & VSM to reduce Galley installation hours in the composite interior build process & improve quality build resulted 95hours/Airplane saving & reduced travel work.

Led ceiling project and created integrated team to reduce the 787interior ceiling cost resulted in saving of 646 hours & moved ceiling back to 2nd position & sustained.

Led Industrial Engineering integrated team, reduced defects in electrical connection at 41/43 & 46/47 composite processes assembly resulted in 80 hours saving.

Evaluated supplier material cost used python Machine Learning (ML) resulted saving of $140K.

Boeing Production System (BPS) Manager -System Inst.

Led lean + 5S plan and facilitated VSM workshop for last stage kitting manufacturing operation.

Developed SIPOCs and data analysis for 777 rate readiness.

Led and Coach employee involvement teams in VSM and other lean+ training & projects. Saved approx. $1.5M in cost avoidance.

Led supply chain kitting with material management to deliver parts by flow days reduced approx. 70% of the manufacturing transaction time per Airplane.

Led the Design and expanded feeder line for 777 SI.

Integrated with PCA & flow parts to feeder line resulted saving 2000 hours per Airplane.

Led Lean+10X / Wire Design Team–Boeing C-130AMP

Optimized C-130 AMP wire design process.

Sr. Industrial Engineering / Lean Specialist - Thales IFE

Led lean (cellular manufacturing) workshop reduced 30% footprint.

Developed production flow to reduce inventory and created Kanban. Worked with designers and suppliers to reduce defects in electronic components

Sr. Industrial / MFG Engineering -Clean room/ Satellite component

Sr. Industrial / MFG Engineering -Ceramic /Engine Component

Developed process for ceramic product Silicon Nitride in the R&D clean room resulted approx. 40% reduction in manufacturing cost.

Evaluated Impaler design and machining defect for APU engine using analytical data and saved approx. 20% in throughput and eliminated waste in production system.

Program Manager leader implemented SAP (PP, MM, PM) and developed requirements for manufacturing.

Sr. Manager, Industrial / Manufacturing Engineer

Developed manpower schedule for manufacturing operation.

Design production flow for new sites.

Managed relocation of the factory and employees from Los Angeles to Gardena, California.

Developed MRP configuration system for sales team to create sales order and manufacturing planner to generate workorder.

Developed lean cellular manufacturing and flow of the product in the new facilities resulted approx. 40% increase in production through-put with minimum manpower.

Developed new product strategy and released product to the manufacturing this enable to reduce product cycle time and cost.

Managed value engineering project saved product cost by 25%.

Program Manager of relocation new brass manufacturing product purchased by company from Detroit MI to Gardena, CA.

Developed logistics plan using 3PL system to transfer product from Detroit to Gardena, California, and supplier delivery.

Managed the design of new layout of 5-axis machine and flow of the product in Gardena. Corporate projection to relocate was one year I relocated and designed facility in the new location within 6 months. This resulted in the company saving $2M.

01/2019-8/2020

2015-2019

2010-2015

2008-2010

2007-2008

2006-2007

2004-2006

1990-2004

Education:

Boeing Leadership Training:

APQP Contributor training

System Theoretical Process Analysis (STPA)

MIT – System Model and Process

Agile training & Certification

Certified Program Management (PMBP & PMI)

Program Managers Emerging Leader Program (PMWE)

Certified Scrum Master SCRUM ALLIANCE

Inside Out Coaching Development

Boeing Talent & Leadership Development

Project Value & Affordability/ System Thinking-

Lean Global Production System (LGPS)

McKinsey & Company – Innovation & Technology

Certified Six Sigma Black Belt & Lean Boeing

Certified Ceramic/Composite Technology

Rutgers University

2022

2019

2019

2019

2017

2016

2015

2009

1997

University:

University of Phoenix Arizona

MBA – Business and Finance

1998-00

University of Southern California (USC)

MS- Industrial and System Engineering / Operation

Research

1980 -82

University of Southern California (USC)

BS-Electrical Engineering / Communication Network

1976 - 80

Training/Certification:

-8 step Boeing Systematic Problem-Solving Methodology (BPSM)

-Completed Aurora training, PNET network, and Pro Model simulation

-VSM, and Advanced facilitator Certificate

-Project management, and innovation

-Hands on consulting, and PM w/ McKinsey 787 program

-Boeing lean trained Qualified Instructor Training

-Capture Value Quality (CVQ) training

-Boeing Production Preparation Process (3P)-certified –coach

-Boeing Intellectual Property (IP)

-Boeing Value Stream Map (VSM) certificate- certified & coach

-Boeing Advanced Root Cause & Corrective Action (RCCA)-SME

-Boeing 10X Lean Engineering training

-Boeing Earn Value Management (EVM)

2018

2016

2016

2015

2015

2013

2012

2010

2008

Computer System /Network:

PDM, IVT, SAP (MM, PP, PM), VISIO, HTML, Pro Model simulation, BORIS, Minitab, AURORA, CMES.CMAD, CDW, Precedence Network (PNET), MS project, Tableau, VELOCITY, EWIRES, REDARS-EID, AI

Reward / Recognition:

- Nominated Engineering Excellence of the year 2023 for ALEI

-Nominated Engineering Excellence of the year (2018) for 767program

- Awarded a reduction of 646 hours of 787 Ceiling Closure

- Awarded 1st place 777 BPS CUP (E-6 Rack Installation System)

- Awarded 2nd place 777 BPS CUP (ESRC TME DELIVERY)

- Received people choice award 777 Duct tool design

- Received ergonomics / safety award for Duct tool design -Boeing AIW

- Nominated for the leadership attribute by C130AMP Sr. Manager in

Airframe exceptional implementation and set high expectation

2023

2019

2016

2013

2012

2010

- Certificate of Recognition exceptional performance $8M cost saving

2009

Intellectual Property

Innovation:

- Developed “Feed Back Loop” Process (IP filing # 15-2803):

Saved 650 hrs. saving.

Currently (2016) 787program testing the method by reducing / eliminating 5000 hrs. of rework.

2016

Professional Affiliations:

-Engineering Alumni Member University of Southern California

-Member -GS&S Lean+10X weekly meeting

-Member -Boeing Six Sigma Black belt (BBN)

-Senior Member - American Institute of Industrial Engineering (AIIE)

-Member - American Production and Inventory Control System (APICS)

Status/Language:

US Citizen/English

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