Process Engineer Manufacturing

Reuben V. Johnson

PROCESS INDUSTRIALIZATION ENGINEER ■ PROCESS ENGINEER ■ CONTINUES IMPROVEMENT ENGINEER ■ EQUIPMENT SPECIALIST ■ MANUFACTURING ENGINEER ■ CONTINUES IMPROVEMENT (CI) ENGINEER

*** ***tral Ln. Apt 916 Lavonia Georga 30553

Phone: 706-***-**** Email: **************@*****.***

~ 18 Years of Specialized Experience in the Automotive Supply Industry ~

Performance-driven Engineering professional offering 28 + years of extensive manufacturing. 20 + years of experience in the automotive supply industry. 15 + years in the Tier 1 automotive supply industry. 12 + years in the engineering field, 8 + years of experience in process industrialization engineering. Project teamwork expertise with an exemplary track record assisting in the success of high-performance projects with working in a cross-functional teams. High degree of proficiency and understanding in business management, program management, lean manufacturing, strategic planning and development, and quality control assurance. Provides objective analysis and innovative solutions to a wide range of manufacturing problems, productivity optimization, safety and environmental issues. Detailed oriented with exceptional communication, interpersonal, and organizational skills.

~ In depth knowledge process industrialization, manufacturing engineering, and plastic welding technology ~

AREA OF EXPERTISE

Industrialization Process Engineering Process / Manufacturing Engineering

Wastewater: Environmental Systems Operator Quality Assurance

Continues Improvement Engineer Risk Management

Project Management 8D Approach to Problem Solving

Improvement Techniques System Analysis

Technical Requirements Staff Leadership

Root Cause Analysis Process Flow Diagrams

Engineering Studies Lean Manufacturing

Lean Manufacturing Research and Development

Research and Development Strategic Planning

EDUCATION

ITT Technical Institute, Greenville, South Carolina

Bachelor of Applied Science (BAS) Electronic and Communication Engineering Technology, 2008

ITT Technical Institute, Greenville, South Carolina

Associate of Applied Sciences (AAS) Electronic Engineering Technology, 1995

PROFESSIONAL EXPERIENCE

TI Automotive 359 Gateway Drive Lavonia, Georga 30553 Manufacturing Process Engineer / Continuous Improvement Facilitator

2023 - Present

Responsibility includes the following – Work with Design and development to implement new production processes and methods, Equipment: Install new equipment, ensure it operates correctly, and troubleshoot problems. Train others to operate new machinery and follow good manufacturing practices. Work with Quality to ensure product quality and meet production standards. Process improvement: Analyze and optimize manufacturing processes to reduce costs and improve efficiency. Production: Oversee production operations, including startup of new production lines. Ensure compliance with regulatory requirements and industry standards. Collaboration with cross-functional teams to drive efficiency and innovation. Manufacturing Process Development to Design, implement, and optimize manufacturing processes ensuring efficiency, quality, and cost-effectiveness. Cross-Functional Collaboration in working with design, engineering, and quality assurance teams to ensure manufacturability of designs and compliance with industry standards and regulations. Review the material requirements considering loss in the process according to the designed production methods (M-BOM). Assist with customer audit and ISO/IATF certification and gate audits. Work with Production Planning to Develop and oversee production plans, schedules, and resource allocation to meet project timelines and production targets. Continuous Improvement: Plan, organize, and lead Kaizen and/or Kaizen Blitz events. Train associates in principles of Lean Manufacturing (5S, 8 Wastes, Value added/non-value-added analysis, Poka yoke & ect.), To leading plant-wide and department level performance improvement initiatives that positively impact cost, quality, safety, material flow, productivity and delivery metrics. Identify opportunities for process improvements and lead initiatives to enhance production efficiency, reduce waste, and improve product quality using Lean and Six Sigma methodologies. Research and recommend appropriate materials and manufacturing techniques for components to meet performance specifications and regulatory requirements. Work with Tooling and Equipment to Design and procure specialized tooling and manufacturing equipment necessary for production processes, ensuring alignment with production capabilities and safety standards. Quality Control: Establish and maintain quality control processes to monitor production output and ensure adherence to engineering specifications and quality standards. Training and Mentorship: Provide training and mentorship to junior engineers and production staff, fostering a culture of safety, quality, and continuous learning. Regulatory Compliance: Ensure compliance with manufacturing regulations, including standards, and participate in audits as required.

SK Batteries America Commerce, Georgia. Electrode Process Engineer

2022 - 2023

Responsibility includes the following - To define detailed production process, identify production influence factors and define process conditions (4M) standards. Monitor the cell reliability test process continuously. Confirm the process standards and set up the equipment operating condition through RMS, Defect Analysis and Quality Improvement. Consult improvement solution and process loss improvement. Examine and consult non-conformity problem of electrode semi-product and cell reliability. Assist with customer audit and ISO/IATF certification and gate audits. Make an inquiry and provide advice for the development and optimization of production-related IT systems (e.g., MES) and data verification system. Assist with New Process Development. Plan and manage the investment budget for newly introduced process and develop new process. Provide process documentation and operating instructions for the newly developed processes. Execute quality control through statistical analysis (regular review of SPC management standard, CPK review, etc.) Develop measures to secure quality and yield while minimizing invested resource (cost, headcount, etc.) Review the quality impact and validity of process addition in accordance with production speed acceleration. Optimize the production process through simplifying or reordering of unit process 4M Productivity. Review the material requirements considering loss in the process according to the designed production methods (M-BOM). Collect feedback on process outliers due to the production’s methods change and take appropriate measure for improvement Other Tasks Assigned

Yamaha Motor Manufacturing Corporation of America (YMMC) Newnan, Ga

Continues Improvement (CI) Engineer E3, 2021 – 2022

Responsibility includes the following- To leading plant-wide and department level performance improvement initiatives that positively impact cost, quality, safety, material flow, productivity and delivery metrics. Develop YMMC's CI culture through targeted training, shop floor Kaizen program, Small Group activities, and Kaizen Blitz events. Facilitate Kaizen and process improvement activities. Works individually or with a team to complete projects following 8 Step Process based on Toyota Production System and Six Sigma methodologies. Provide CI support to shop floor associates, production managers, and other engineering departments. Design, develop, and implement improved work flows. Partner with Manufacturing Engineering to create/update work instructions, visual aids, and process standards for production operations. Plan, organize, and lead week-long Kaizen Blitz events. Train YMMC Associates in principles of Lean Manufacturing (5S, 8 Wastes, Value added/non-value-added analysis, Poka yoke), Theoretical Value Production, PFMEA, and Formal Problem-Solving techniques. Mentor and develop CI department interns (quarterly rotation). Provide direction to CI department technicians. Develop and maintain time study documents. Conducts Value Added Analysis (VAA). Perform classic IE time studies and optimize labor line balance. Identify and troubleshoot inefficient work processes. Perform process analysis, design, and refinement. Identify opportunities, participate, and complete projects as identified by CI department annual goals. Perform value stream mapping. Update master projects lists. Provide summary progress reports for management review. Champion Kaizen and Small Group programs.

Horton Inc, Westminster, South Carolina

Manufacturing Engineer, 2020 – 2021

Responsibility included the following - Main area of responsibility Injection Molding, Wastewater Environmental System Operator, Process Assembly, E-Coat painting system and Powder Coating painting system. Responsible for establishing and implementing the most cost-efficient methods for production. Plans and coordinates the activities necessary to produce specified products within safety, quality and cost standards. Accountable for solving technical problems associated with the facilities and machines used in the manufacturing process, and for developing recommendations for process improvements. Develops and improves production processes including design, and implementation of process systems. Works with production staff and others to identify opportunities for improvement, which may include "bottlenecks" in the process or methods. Studies existing fixtures/tooling and helps develop modifications to improve accuracy and efficiency. Studies existing fixtures, tooling, equipment and automation to develop design modifications to improve accuracy and efficiency. Designs new fixtures, tooling, equipment and automation for plant processes and upgrades of current machines to improve quality and efficiency. Develops cost/benefit analysis and layout for future purchases of machinery or development of new work cells in response to anticipated production capacity needs, writing proposals for capital improvements. Assists with the preparation of cost estimates for given products by analyzing the production process and costing each step, providing information to be used by corporate engineering and sales staff for proposals and product pricing. Designs the manufacturing process for new parts or products by breaking down the process into steps, placing those steps in the correct sequence, and assigning the process to the most efficient available machine or cell and maintains process documentation when modifications to existing process are made. Writes and reviews engineering change requests (ECO's) to determine whether proposed changes require process modifications and either recommends that the change be approved or recommends that the ECO not be approved based on lack of feasibility or excessive cost. Changes process documentation to conform to new methods. Works with supervisors to train production staff in the use new methods. Provides direct problem-solving support to the production and quality functions using advanced statistical techniques and methodologies. Troubleshoots and solves problems for assembly, machining and specific areas of production. Oversees the use of quality tools such as statistical process control, control plans, answering questions and helping production workers with development of proper technique. Designs system processes to assure compliance with quality and engineering specifications. Conducts direct labor studies using acceptable engineering practices and establish standards on operation, set up, and work station layout. Provides direct problem-solving support to the production & maintenance functions. Works with IT department to oversee the database administration of appropriate systems. Work with suppliers and customers via phone & email to support manufacturing processes.

Draexlmaier Automotive, Duncan, South Carolina

Industrialization Process Engineer, 2012 – 2020

North America Senior Application Engineering Coordination in Plastic Welding Technology

Responsibility included the following - Plans and implements technologies (injection molding, press lamination, robotic automation, milling, punching & plastic welding) in support of project industrialization and series production. Responsible, customer service and success oriented collaborative development of processes and production of products representative of company core competencies with a specific focus on welding technologies. Provide leadership in lean process development track from the discovery phase through mature development. Ensure production feasible solutions are provided to the organization. Research of new processes and materials for continuous improvement and higher efficiency is imperative. Provides cost estimation (Invest, Budget), technical specification and request for quotes. Evaluates concepts with technical and financial focus for facility and process equipment. Creation of prototypes and sample parts in support of continuous improvement studies and consultation in design of parts and preparation of basic data for calculations. Focus to maintain cooperative development efforts for programs and to assure transition to production. Develops key parameter for requirement manuals, processes windows as well as accounting data sheets for development guidelines, and specifications for processing. Evaluates, coordinates and compiles bidder circle, call for bids, offers evaluation, recommendation for the award of contract, acceptance of the equipment from the suppliers and handing over to the operator. Finds the optimum solutions regarding costs, quality, ergonomics, technical innovation and environment. Determines root causes and conducts analysis on equipment defects and failures while implementing corrective measures. Identifies critical process steps and participates in establishing production/maintenance control plans and process control strategies. Ensures additional materials and parts are available for machine run-ins, capability studies, validation efforts, and studies. Participation in PFMEA, DFMEA etc. as a team member for processing related topics; while ensuring proper risk assessments are conducted and counter measures are clearly defined. Maintains reliable and safe manufacturing systems while improving production rates, efficiencies, yields, costs, and uptime improvements. Participates in trial activity with Product Development, to ensure successful launches of new products and to improve existing products. Assisted production and maintenance in isolating complex manufacturing issues whether it is in process, material, or machine functionality related. Reduces cycle times and increases efficiency of automated equipment. Eliminated manufacturing waste through process optimization. (Time, scrap, effort, etc.) Maintained and update production documentation. (Process Flow, PFMEA, Work Instructions, machine manual, machine drawings, backup programs, etc.) Assists in program start-ups involving processes, equipment, machinery, and tools (fixtures and jigs). Created standards for new equipment and processes set up in series production. Reviewed product engineering changes (PI) and give feedback for implementation cost. Investigated new technologies to enable DAA to stay competitive in automotive manufacturing industry. Responsible for assisting Maintenance to understand what PMs and spare parts are required. Project (BMW F25, F26, F15, F16, G01, G02, G05, G06, G07) (GM Cadillac CTX, XTS) (Tesla Model Y, Model 3, Model S)

Process Engineering Technician, 2011 – 2012

Responsibility included the following - Provided feedback and recommended changes to engineering to achieve cost downs and improve product manufacturability, procedures, and manufacturing equipment. Troubleshoot and repair industrial machinery. Eliminated manufacturing waste through process optimization and changing equipment parameters; which reduced cycle times and increased efficiency. Assisted production and maintenance in isolating complex manufacturing issues whether it is in process, material, or machine functionality related. Investigated new technologies which enabled Draexlmaier Automotive to have a strong competitive edge in the Automotive Manufacturing Industry. Maintained equipment documentation that included machine manuals, drawings, and backup programs. Streamlined and updated production documentation to include; process flow, PFMEA, and work instructions. Assisted in program start-ups involving processes, equipment, machinery, and tools. Implemented standards for new equipment and processes set up in series production. Reviewed product engineering changes (PI) and gave feedback for implementation cost.

TI Automotive, Hartwell, Georgia

Lead Process Technician, 2005 – 2011

Responsibility included the following - Main area of responsibility was blow molding and plastic welding

Developed and integrated processes for new products/projects on the blow molding machine and plastic welding processes. Performed engineering builds and quality testing with minimal documentation and/or instruction. Collected and analyzed critical function part dimension data to determine if parts were within customer and company specifications. Collaborated with technicians and engineers in reviewing and assessing internal drawings and specifications. Provided effective training and development for entry level process technicians; improving productivity. Assisted with the design and development of new products based on customer specification (prototype). Verified the process to make sure it is within the required specifications to minimize the process and cut down on cycle time and the reduction of strap. Troubleshoot and repair industrial machinery. Repaired and maintained all robotic, down line machinery, feed system, and blow molding machinery. Assisted management with identifying manpower needs. Lead and manage the Process Technician team.

US Engine Valve, Westminster, SC

Engineering Technician, 2004 – 2005

Responsibility included the following - Training of maintenance in basic AC, DC theory to basic troubleshooting techniques. Troubleshoot and repair industrial machinery. Assisted maintenance with technical support in higher technical problems. Performed assigned projects in which sometimes included the up-grade of production equipment with new technology. Applied changes to PLC’s logic as needed are assigned. Performed routine and non-routine electrical maintenance to equipment. Responded to equipment breakdowns with effective results. Installed new equipment and performed the run-off. Performed preventive maintenance as scheduled to equipment. Performed a part of the maintenance technician yearly reviews. Worked as an individual or in a team to complete assigned task.

Tenneco (Monroe Auto Equipment Company), Hartwell, South Carolina

Industrial Maintenance Electrician, 2001 – 2004

Responsibility included the following - Performed routine and non-routine electrical and mechanical maintenance of production equipment in an assigned department. Performed preventive maintenance as scheduled and repairs as needed, ensuring minimum downtime in production. Responded to production line machinery breakdowns with effective results. Installed and upgraded production machinery as need. Troubleshoot and repair industrial machinery. Worked as an individual or in a team to complete assigned projects.

ADDITIONAL PROFESSIONAL EXPERIENCE

Wellstone Mills formerly known as TNS Mills (Textile) Lavonia, Georgia

Shift Electrician, 1995 – 2001

US Personnel Temporary Services; (Student)

Material Handler, 1993 – 1995

PROFESSIONAL DEVELOPMENT

AIAG & VDA Process FMEA Understanding and implementing with control plans, Certificate of completion 2025

Environmental Systems Operator, Certificate of completion in Wastewater: 2020

Leadership for engineering Workshop certificate of completion November 8, 2018

ABB University Training Center, Programming 1 Material Handling Certificate of completion, 2017

Level 1: Simulation and 5S Certificate of Completion Draexlmaier, 2015

Level 2: Kaizen Facilitator Certificate of Completion Draexlmaier, 2015

Level 3: DVP Project Improvement & System Certificate of Completion Draexlmaier, 2015

Fundamentals of Project Management / Basic SEP Training Certificate of Completion Draexlmaier, 2013

Using the 8-D Approach (Basic) Certificate of Completion Draexlmaier, 2014

Using the 8-D Approach (Advanced) Certificate of Completion Draexlmaier, 2014

Fundamentals of Project Management / Basic SEP Training Certificate of Completion Draexlmaier, 2013

Communication and Interpersonal Style Certificate of Completion Draexlmaier, 2013

PLM – Team Center (Basic) Certificate of Completion Draexlmaier, 2013

Conflict Management I and II (Combo) Certificate of Completion Draexlmaier, 2012

Presentations and Meetings Certificate of Completion Draexlmaier, 2012

ABB University Training Center, Electrical Troubleshooting, Certificate of completion 2007

Rockwell Technical Training, Maintenance and Troubleshooting SLC 500 System Certificate, 2004

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