Manufacturing Engineer - Product and Processes

Roy R. Johnson II

***********@*******.*** *** Roberts Dr. Greenwood, SC 29649 336-***-****

Manufacturing Engineer

Adding Value to Products and Processes through Resourceful and Timely Engineering

Mechanical Proficiency, Electrical Skills, Interpersonal Skills, Innovative, High Energy, Articulate, Time Driven, Self Motivated

Proven Results - Six Sigma Green Belt Certified

Hablo Espanol

EXPERIENCE

EATON CORPORATION, ELECTRICAL DIVISION 2005 – 2009

MANUFACTURING ENGINEER , GREENWOOD, SC (2008-2009)

LOW VOLTAGE BUSWAY MANUFACTURING

•Managed product launch with reduced manufacturing time (~50%) by changing fabrication, fixturing, assembly, stocking, lead time and kanban issues. Supported prototyping, UL testing & post design service providing, PFMEA, control plan, test plan, verification strategy, technical documentation, method sheets, SOP’s, calculated manufacturing cost and designed packaging, increasing sales.

•Partnered, to design, fabricate and install (hands-on) a conveyor system to capture (~85%) more aluminum chips from sawing operation, reducing cleanup and safety issues. The new conveyor averted threatened lawsuits from customers. (Received Award)

•Reduced sawdust dispersion (~95%), and increased efficiency with operation time reduced (~70%) while allowing anyone to operate new saw safely by introducing correct equipment. Improved OSHA safety (exposed saw blade vs. hidden) and employee satisfaction (removing worry of injury) by involving team input and securing management approval.

•Supported 3 record-setting production months by creating and revising “method sheets” and designing manufacturing aids to ensure quality, increase efficiency and reduce rework.

•Closed 100’s of safety issues in preparation for successful corporate safety audit. (Received Award)

•Installed and enhanced new epoxy powder reclaim system. Reduced scrap ($12,000/yr), increased efficiency (~30% less cleanup), improved safety with (~75%) less airborne contaminates and raised employee satisfaction. (Received Award)

SUPERVISOR-GLOBAL SERVICES LOGISTICS CENTER, RALEIGH, NC (2007-2008)

UPS Systems Repair – was asked to be supervisor for turnaround.

•Achieved business performance objectives by: reducing vendor expedite costs (~15%), increasing customer pricing (~10%), introducing team cost savings ($250,000), reducing production space (28%) while improving production (~6%), lowering budget expenses (15%), shipping on time (91.6% surpassing 90% goal), limiting Defects Per Million Opportunities (DPMO) actual of (1776 exceeding 2600 goal), underscoring value of business unit.

•Managed interface between logistics, vendors, customer service, safety, maintenance, engineering, marketing and IT departments. Provided employee evaluations, resolving employee and attendance issues improving employee well being, morale and production. Established employee cross training and production quantities process. Championed safety team & production line move.

DEVELOPMENT ENGINEER, TIJUANA, MX & RALEIGH, NC (2005-2007)

Lean/Quality/Project Management/Localization

UPS Manufacturing/Design and Power Factor Correction

•Stepped into Project Manager Role after PM resigned. Personally redesigning power factor product family, resulting in reduced project cost ($286,000 to $110,000), shrinking product cost ($93,000/year), shorting assembly time (~25%), reducing parts (~20%), and eliminating complaints of old design. Finished project on time. (Received Award)

•Championed multidisciplinary project by benchmarking European and American ECN process, drafting a global ECN process value stream map (VSM). This followed introduction of Asian production facilities to ensure standardization. (Received Award)

•Achieved Six Sigma Green Belt Certification by managing most problematic supplier using corrective actions, tracking, 8D’s, and in-house screening of 12,854 electronic boards following Six Sigma methodology to reduce circuit board defects from (222,000 to 3,000 DPMO) and incoming defects from (17 to 3) through a Gage R&R design of experiment (DOE).

•Used ISO/OSHA guidelines as team player to discover, capture and initiate closure process of 287 action items from production line validations, improving safety, ESD issues, lean and 5S with continuous value added improvement.

•Supported, guided and motivated personnel to raise factory lean score from (3.5 to 4.3) of possible 5, by creating: VSM’s, charting, tracking, matrices and action plans as acting lean coordinator.

•Saved ($347,000) with 10 projects in just 4 months using conceptual CAD drawings and lean methodology. Modified existing UPS products and OEM UPS products through data analysis and ECR/ECN/ECO change management process while continuing high volume electronic production.

NC A&T UNIVERSITY, GREENSBORO, NC (2002-2005) Teaching/Researching Assistant – Student Clock Manufacturing System

ABB CIRCUIT BREAKER DIVISION, FLORENCE, SC (1996-2001)

Product Designer - Low/Medium Voltage Switches/Breakers/Switchgear

•Designed/redesigned hundreds of parts/assemblies for MV and LV breakers and switches (>250 ECN’s in 5 yrs) including a 38kV medium voltage power distribution ground and test device. Solely designing, prototyping, hipot testing @110kV, and custom building for satisfied customer when other designer had failed.

•Developed internal database and trained shop floor employees for capturing (400+) product and manufacturing issues. Partnered with engineers in referring to database for prioritization, tracking, ECN’s generation, and issue resolution, closing feedback loop by placing resolution and ECN number back in database to promote zero defects.

EDUCATION

Masters of Science, Industrial Engineering (2005) N C A&T University, Greensboro, NC

Bachelors of Business Administration (2001) Francis Marion University, Florence, SC

Awards, Organizations and Activities

•Hablo y intiendo bien el idioma espanol

•5 Eaton Service Excellence Awards

•Six Sigma Green Belt Certified

•Volunteer Service – Hospital, Triathlon, Kids Hockey Coach, Mexican Orphanage.

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