Carl Morrison Email & Phone Number

United States

Houston, Texas

Direct a dynamic team of three engineers, instituting a culture of collaboration and innovation that catalyzed key project achievements, including the design and execution of sophisticated engineering strategies, compression of project delivery timelines, and elevation of team performance and technical acumen, closely monitored through productivity metrics and skill development indices.Orchestrated a groundbreaking initiative that propelled unit per hour (UPH) productivity from 0.80 exceeding 1.35 UPH, through meticulous bottleneck analysis, process refinement, and enhancement of warehouse logistics, resulting in streamlined operations, a surge in production throughput, and realization of $2 million in cost efficiencies. Spearheaded the attainment of ISO 9001 certification, affirming adherence to global quality management standards, by facilitating auditor interactions, budgeting for infrastructure enhancements, integrating 5S methodologies, refining operational and quality protocols, and upskilling technical personnel, while preparing for ISO 45001 certification to underscore a commitment to occupational health and safety.Amplified first pass yield (FPY) from approximately 70% to 92%, showcasing marked advancements in manufacturing quality and process efficiency through the deployment of process animations, minimization of redundant operations, and optimization of material logistics, thereby reducing material rework intervals from one day to 45 minutes.Centralized part consumption metrics, optimizing inventory control and expediting component allocation to technical staff, thus enhancing operational fluency and minimizing production interruptions. Additionally, deployed cost reduction strategies and sophisticated inventory tracking technologies, further refining engineering operations and maximizing resource efficiency.

United States

Achieved a cost reduction of $6 million through the design and implementation of cost-efficient machinery and component solutions, significantly enhancing production efficiency and throughput within stringent timelines, while fully complying with project requirements and product specifications. This initiative was instrumental in optimizing manufacturing processes, contributing to substantial cost savings and operational excellence.Directed a comprehensive team comprising 2+ engineers, 15+ production management personnel, 4+ maintenance operatives, and 2+ quality assurance staff, overseeing the execution of medium to large-scale capital projects valued between $500K and $20M. These projects span critical sectors such as Powertrain, Chassis, and Tube Mill operations, ensuring projects are delivered on time, within budget, and to the highest quality standards.In a pivotal role focused on professional development, spearheaded the training of new engineers in root cause analysis utilizing the 5-Why technique and effective communication across diverse stakeholder groups. Accountable for ensuring the completion of training modules, provision of advanced technical resources, and alignment of project objectives with overarching company goals, thereby enhancing team capabilities and project outcomes.Authored comprehensive Process Failure Mode and Effects Analysis (PFMEA) documentation and defined entire project scopes. Spearheaded the improvement and setup of numerous machines including Fanuc Robots, CNC Tube Bending Machines, Automatic Projection Welding Machines, Fin Mills, Burr Oak systems, Cosmo Leak Testers, and Coordinate Measuring Machines, among others. This effort markedly improved operational reliability and production efficiency.

3700 Bay Area Blvd Houston, Tx

Delivered a comprehensive presentation on the Accelerated Life Test of the Carbon Dioxide Removal Assembly (CDRA) to stakeholders at Boeing and NASA in Houston, showcasing project milestones and technical findings.Authored a detailed 40-page technical report, devised standard operating procedures, and established CDRA project timelines to ensure timely achievement of project deliverables.Engineered and constructed the CDRA experimental setup, surpassing Boeing specifications, to demonstrate advanced carbon dioxide removal capabilities.Executed rigorous experimental protocols to validate the CDRA's functionality, generating critical data to support system performance and efficacy.Assembled the Carbon Dioxide Removal Assembly System, significantly contributing to the life support capabilities of the International Space Station Capsule.Orchestrated the development, scheduling, and execution of daily CDRA tasks, ensuring project milestones were met ahead of schedule through diligent planning and coordination.Conducted extensive thermodynamic and fluid dynamic calculations, including copper pipe length, mass flow rates, heat exchange metrics, and applied gas laws to ascertain the gas mixture's thermo-physical properties, facilitating optimal design and operational parameters for the CDRA.Finalized the AutoCAD design for the Carbon Dioxide Removal Assembly, laying the groundwork for precise manufacturing and assembly processes.