Carl Merhar Email & Phone Number

Jessup, Maryland, United States

Towson, Maryland, United States

• Directed a 15 person global team identifying, evaluating, funding, and implementing automation projects to plants worldwide.
• Wrote and submitted project plans and capital requests for automation and product transfers
• Delivered roughly $5M cost saving year over year in productivity
• Created and implemented a tollgate process for automation development and commissioning
• Worked with cross-functional teams to evaluate location of manufacture for projects and product lines
• Collaborated with plants to evaluate and optimize manual and automated processes for lean manufacturing

• Managed a 4 person team
• Developed automation projects from ideation to implementation working with overseas suppliers
• Delivered roughly $500k cost savings year over year in productivity
• Served as manufacturing representative on New Product introduction teams supplying DFA/DFM input in the early stages of design and providing support to the plant through new product launch
• Conducted DOEs and GR&Rs to support manufacturing process development
• Provided Make v Make and Make v Buy analyses for new products and product transfers

Towson, Maryland, United States

• Managed a 4 person team
• Served as manufacturing representative on New Product introduction teams supplying DFA/DFM input in the early stages of design and providing support to the plant through new product launch
• Managed development new product cost BOMs
• Conducted DOEs and GR&Rs to support manufacturing process development
• Provided Make v Make and Make v Buy analyses for new products and product transfers
• Mentored young engineers on DFM, stack-ups, datum selection for various processes

Towson, Maryland, United States

Towson, Maryland, United States

- Led Warranty and value improvement projects across the tool portfolio- Launched an award winning new circular saw into the market

• Directed a 5 person team designing and delivering new woodworking and metal working tools – DeWalt and Delta - with a focus on innovation
• Engaged with international teams (internal and external) to deliver products that meet marketing specifications, industry safety requirements (UL and CSA), and cost targets
• Wrote and submitted regulatory documentation for new products
• Drove warranty reduction projects for the stationary and benchtop woodworking portfolio

Jackson, Tennessee, United States

• Led a 3 person team designing and delivering new woodworking and metal working tools – DeWalt and Delta
• Worked with international teams (internal and external) to deliver products that meet marketing specifications, industry safety requirements (UL and CSA), and cost targets
• Wrote and submitted regulatory documentation for new products
• Drove warranty reduction projects for the stationary and benchtop woodworking portfolio

Towson, MD

- New product development professional power tools- Modeled and detailed parts in 3D and 2D to manufacturing tolerances, performed stack-ups on full systems, - Led team in switch from CADAM to CATIA- Worked with cross-functional team - marketing, quality, plant and suppliers to deliver product to regulatory, cost and user requirements

Contract Designer DeWalt Power Tools - Modeled and detailed parts in CATIA- Mentored engineers on 3D modeling.

• Assisted Belgian team and 1st tier supplier to deliver the first Lost Core injection Molded active intake manifold for Chrysler 3.2L and 3.5L engine platform
• Prepared and presented project proposals and quotes for new business

Bsme, Mechanical Engineering

Activities and Societies: Tau Beta Pi Concentrations in machine design and control system design.

Msme, Mechanical Engineering

Specialties in product design and injection molding