1. FRANK McDONALD
9590 Meridian Park Avenue, Las Vegas, NV 89147
Cell: (702) 525-3908 fmcdonaldlv@gmail.com
SUMMARY
Key player of manufacturing facilities: successfully implementing systems and procedures,
providing leadership, oversight, and guidance to ensure effective quality world class operations.
RELEVANT EXPERIENCE
CPI CARD GROUP, North Las Vegas, NV
CPICard Group is a singlesource global provider of payment solutions including card production, card
personalization, mobile technologies and fulfillment services with 30 years of experience in the
payments market.
Materials Manager May 2014 - 2015
Oversaw all warehousing, inventory, and receiving activity and operations for both the card
manufacturing and card services departments.
 Reduced active inventory by 15% and obsolete inventory by 21%, to an all-time low, while
maintaining sufficient quantities to meet all manufacturing and personalization requirements.
 Successfully implemented an alternative inventory/locator program to monitor and track
specific ‘non-inventory’ items that were required for individual jobs for card services.
 Identified obsolete items in warehouse inventory and greatly reduced their quantities by
finding internal alternate uses, selling, or destroying and selling to recyclers.
 Maintained acceptable levels of raw material items such as plastic core, packaging,
magnetic stripes, and hot stamp foils & panels to meet all manufacturing and fulfillment
requirements
Production & Final Inspection Manager 2010 – May 2014
Managed all production processes and final inspection activity for the card manufacturing
department. Duties included maintaining proper staffing requirements, meeting shipping
requirements of finished cards, implementing quality improvement processes and operator
training and cross-training programs.
 Implemented Cross Training program in card manufacturing and final inspection areas that
resulted in 90% of the workers having the ability to run at least one other piece of equipment
of another process
 Reorganized production floor and final inspection areas to improve product flow. Developed
and implemented good housekeeping processes, production equipment efficiency reporting,
and reliable scrap processes and reporting
 Participated in and implemented quality improvement processes, such as Kaizen event for
Edge Cut process, to help optimize production efficiencies
CPI Card Group Sub-contractor Representative 2009 - 2010
Responsible for on-site overseeing and monitoring out of state sub-contractors’ personalization
and affixing operation of CPI Card Group, Nevada supplied cards.
 Developed and implemented reporting documents that were sent daily to key personnel at
the subcontractors and CPI – Nevada keeping them abreast of the progress of the individual
jobs.
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2. ARROWEYE SOLUTIONS, Henderson, NV
Arroweye Solutions is an innovative payment card solution and technology provider of highly
efficient, on-demand and cost effective card marketing and patented production solutions of
personalized cards for the financial industry.
Operations Manager Sept. 2008 – Jan. 2009
Contracted to manage and oversee the production operation including efficiency evaluations of
the manufacturing processes.
 Developed a manual depicting metrics of each process efficiency with suggested solutions
to solve any inefficiency issues
CPI CARD GROUP, North Las Vegas, NV
Quality Manager 2004 – Sept. 2008
From Plant start-up, established and implemented a Quality System that monitors all
processes of plastic card manufacturing to assure compliance to all applicable ISO and
customer requirements. This includes weekly, monthly, and quarterly reporting to Management
of all Key indicators i.e. Customer Returns, Internal Scrap, Product on Hold, and AQL Lot
inspection results utilizing Minitab and Excel for Pareto charting.
 Implemented Quality System that resulted in reduction of Customer Returns by 68% the 1st
year, another 60% the 2nd
year, to less than 0.2% of shipped cards by end of year 3.
Assumed responsibility of the ISO Quality System which included the upgrading all of the
procedures and resulted in retention of the company’s ISO certification
 Utilized Six Sigma tools such as DPMO tracking and reporting of the main processes of
manufacturing (printing, lamination, die cutting) and service bureau (personalization,
affixing, shipping); gage R&R studies of Mag stripe and Bar Code analyzers; and formal
report outs of processes (lamination completed)
 Exhibited good leadership and judgment and was appointed temporary Plant Manager
during his absence
ENEM Ensambles y Empaques de Mexico, S.A. de C.V. Tijuana, Mexico
Manufacturing and Product Engineering 2003 - 2004
 Contracted by local owners to develop and establish a manufacturing and packaging facility
that had roto-molding, vacuum metalizing, sewing, and decorating processing capabilities.
 Developed and implemented all quality standards required for each process and project.
Sundance Sales, Inc. Murrieta, CA
Sales Engineer and Representative San Diego County 2000 - 2002
 Sales of manufacturing commodities and sub-con. processes
 Participated in establishment and launching of Web site (LoveMyTown) that promoted and
showcased Local Businesses and available Real Estate by individual towns. Utilized 360
degree panoramic views of each establishment and published it on the Web Site with its
pertinent information.
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3. MATTEL, Inc. El Segundo, CA 1973 - 2000
Mattel, Inc. designs, manufactures, and markets a range of toy products worldwide
Director of Engineering and New Toy Development
Mabamex S.A. DE C.V. – Mattel Tijuana, Mexico Manufacturing Facility
Liaison Engineer for Mattel’s Manufacturing Facilities located in Mexico
Mattel, Inc. El Segundo, CA
Director of Quality Control and Injection Molding
Montoi S.A. DE C.V. – Mattel Monterrey, Mexico Manufacturing Facility
Operations Manager
East Coast Molding, Subsidiary of Mattel Toys – North Brunswick, NJ
Selected Accomplishments with Mattel
 Mattel Worldwide Excellence Award – Assisted in the design and debug of a high profiled
new product, which resulted with a worldwide product start and availability 2 weeks ahead
of original projected schedule.
 Mattel President Award – Implemented program that resulted with a reduction of rejects and
scrap to less than 0.5% while presiding as Operations Manager of a Mattel, Inc. injection
molding plant.
 Restructured Engineering Department of the Mattel, Inc. Tijuana, Mexico manufacturing
facility resulting with a 20% reduction of market availability lead-time of new products.
 Managed the development of an internal Engineering Handbook, implemented to
standardize procedures and optimize the problem solving process and minimize time-to-
market for new products.
 Initiated the cross-functional Product Teams concept and successfully integrated them into
the corporate multi-plant, product development process
 Established and managed the Quality Improvement Process into the Mattel, Inc. Monterrey,
Mexico manufacturing plant resulting in a 10% reduction in cost of quality.
 Selected by Mattel corporate to identify Quality requirements of a new Mattel, Inc, New
Jersey 24/7 Injection Molding facility and manage the complete set-up and development of
the Quality Control Department. Initiated closed-loop processes and procedures, all
contributing to the plant’s overall reduction of scrap and reject rate to less than 0.5%, a
$30,000.00 per month cost of quality Savings.
TRAINING AND EDUCATION
BS Mechanical Engineering, UNIVERSITY OF DAYTON, Dayton, OH
Training in ISO 9000, 9001, 9002 policy and procedure development
Certificate Quality Improvement Management
Certificate in Fundamentals of Plastics, NY
Focus 2000 Productivity Improvement training and leader of implementing process
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