MARTIN JOHNS

OBJECTIVE

Join a motivated team as a full time hands-on Equipment/Controls Engineer (manufacturing

or maintenance)

EXPERIENCE

Hella Lighting Corporation York, SC 3/2002 – 7/2010

Hella Lighting Corp. is a tier one supplier for OEM automotive lighting. Hella is one of the top 50 automotive suppliers in the world. There are over 23,000 employees working in 70 facilities worldwide. The York facility, now closed, employed over 600 employees and had over $100M+ department revenue per year. The facility operated 3 shifts 6 days /week during peak production and supplied BMW, Mercedes, GM, Ford, PACCAR heavy trucks, and Chrysler.

Equipment Engineer, Assembly

*Equipment Engineering activities for 16 Headlamp assembly lines

-Established local vendors and specified complete details to obtain competitive bids.

*Tooling and equipment modifications for assembly tooling: Design, construction, and programming

-Design changes to improve efficiency

-Ergonomic improvements

-Warranty and quality improvements

-Complete machine design and construction.

*Hired, trained and supervised Assembly Maintenance Technicians

-Established pay grade, advancement, and evaluation matrix for 8 technicians over 3 shifts

-Detailed Preventive Maintenance plans for all equipment and machine in assembly department.

*Fully Integrated and maintained Cognex, VisiCon and Keyence vision systems

-Complete PLC integration

-Profibus integration

-Developed job specific lighting

*Lead troubleshooting and repair of assembly equipment

-11 Adhesive pumping systems (ITW, Nordson, Reinhardt Technik)

-16 Automatic leak testing stations

-7 Keyence laser marking systems

-17 ABB and Motoman robot systems (Adhesive application, pick and place, pre-treatment)

-3 plasma systems, Open air technology

-50 automated assembly work cells with quick change capability

*Developed data acquisition system for assembly lines using OPC server

-Overhead display showing real time production status, customized for each line

-Networked system for display on PC in any office area

*Coordinated activities for international transfer of assembly lines

-Transferred physical equipment and product-specific knowledge

-Facilitated transfers within the company and to competitors

-Decommissioning and removal of the manufacturing equipment from the facility

North American Lighting Flora, IL 11/1988 – 3/2002

4 plant, 3500+ Employees

Automotive headlamps and signal lamps

3 shift production, 6 days/week

Equipment Engineer

*Developed controls for standard work cell stations

-Designed and maintained standardized controls for 250 work cells and 45 glue robots

-Made continuous mechanical and electrical changes to meet the work floor needs

-Improved design of all cells stations to pass 1 million cycle test

-Maintained a standard design to satisfy production standards at three separate facilities

-Created automatic quick-change program for all work cells

-Installed controls for 35 robotic work cells

*Controlled equipment budget and procurement of assembly lines ($50K-$1.2M/project)

-Forecasted cost for assembly tooling for future business

-Made complete specification for equipment to meet production plan and rates

-Acquired competitive quotes for all equipment

-Selected vendors and controlled timing for entire assembly line fabrication and delivery

-Supported equipment through development, SOP and service status (10 years)

*Trained technical maintenance staff of 22 (3 shifts)

-Instructed PLC class for all technicians (12 session class)

-Created testing and pay grade matrix for all technicians

-Developed preventive maintenance schedules for equipment

-Maintained inventory of spare parts for all assembly equipment

EDUCATION

Southern Illinois University – Carbondale, IL (1987)

Associates degree in Applied Science / Electronics Technology

Training

*TMMC (Toyota) kaizen philosophy training at Koito Mfg. Japan 4 weeks (1994)

*ABB robot basic and advanced training Michigan (2002-2004)

*Mototman robotics ERC, MRC and XRC. (1989-1999)

SKILLS

*Microsoft Office (Word, Excel, PowerPoint, Project)

*PLC programming and troubleshooting with Mitsubishi

*RS232, Ethernet, and Profibus program integration

*ABB Robot programming

*Motoman robot system integration and programming

*Keyence laser marking integration and programming

*Keyence and Cognex vision systems integration and programming

*8D issue documentation and resolution process

*Fishbone diagram, team problem solving

*Machine tool operation – tooling fabrication (basic mill, lathe and grinding)

*Resin castings for prototype tooling and fixtures

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