John Toal Email & Phone Number

Monroe Township, Nj, Us

Site Manager at TE Connectivity’s American Sensors Technologies site, a $12 million global leader in MEMS based pressure sensors.Managing the site during the 11-month transfer of production from New Jersey to Hermosillo Mexico.Managed equipment and material moves to minimize impact to lead times of customer orders.Reduced back log by 45% in preparation for the transfer.Maintained a ship to customer request STR of over 90% and past-due to request under $100K in a high mix, low volume business.Ran Daily Tier system of accountability, achievement, reconciliation on Key Performance Indicators.

Schaffhausen, Ch

Manage day-to-day operation at TE Connectivity’s Macro Sensors site, a $5 million global leader in linier position sensors (LVDT’s).Promoted from Manufacturing Engineer II to Site Manager within 6 months.Directly oversaw all manufacturing, scheduling, purchasing and inventory.Designed and implemented changes in manufacturing, scheduling, purchasing and inventory to fix both STS, and STR, KPIs by over 15%, reduced the past-due backlog from $107k to $36k in 3 weeks.Optimized work instructions and reduce non-value adding steps in production process to ease the transferring of production to a new facility Mexico.Traveled to other manufacturing sites to help the transfer of production from New Jersey to Virginia and Mexico.Implemented the migration of the legacy MRP system, with over 6k part numbers from DBA to SAP within 3 days.Created and updated all routers in SAP and conducted time studies to validate legacy labor times. Optimized all manufacturing flow, processes, and procedures for in-house products being manufactured to our control drawings.Supervised all Quality Assurance issues and concerns, acted as contact for all site audits, and worked with outside consultant Quality Manager. Designed, managed, and configured tooling to support all facets of product manufacturing.Documented tooling and fixtures utilizing AutoCAD and Inventor.Created or improved manufacturing process and operator training instructions to conform to new TE policies.Led the implementation of TEOA, TE version of lean manufacturing.Reviewed all new designs with Design Engineering and Sales for possible manufacturing and quality issues.Worked with Design Engineering to update and change any documentation or designs to increase manufacturability and quality while reducing cost, scrap and labor time, based on document analyses.

Philadelphia, Pa, Us

Designed a system of checks and balances to reduce gaps in documenting, turning up, and provisioning new circuits reducing cycle time by 20%.Deployed, scheduled installation, provisioned, and tested new equipment into the network to increase the bandwidth of the company's internet protocol backbone network and transport infrastructure.Led technicians remotely through installation process of equipment while monitoring any disruption in live traffic.Responsible for documenting all changes within the Comcast Central backbone network.Achieved team goals by working with suppliers to improve design of new products. Designed a process with vendor to reduce false alarms in the system by 45%.

Schaffhausen, Ch

Designed both mechanical and electrical aspects of Linear Variable Differential Transformers (LVDT) to meet customer needs and comply with ATEX and CSA certifications for hazardous locations.Redesigned spring assist LVDT’s based on Fatigue and Load Analysis.Worked with customers to create custom LVDT’s that could be incorporated in their current system design.Documented new & old LVDT designs by creating CAD drawings, BOM’s in DBA, and obtaining appropriate test data.Created Engineering Change Orders, Engineering Work Instructions and Final Assembly Test procedures.Designed test fixtures to validate and verify that completed product satisfied all requirements and specifications. Designed new and updated old tooling to streamline production and testing of units.Utilized SolidWorks and Turbo CAD to design 3-D parts and CAD drawings for documentation of units and tooling.Designed a low-cost pressure chamber for pressure testing deep sea units, anticipated saving of $40k a year.Implement an automated computer winder into production to replace hand winding coils.Developed an automated LVDT linearization test station to reduce production time and cost, reduced test time by 65%.Analyzed and improved LVDT models that have high failure rates and redesign to increase yield by 32%.Machined various prototype parts to tolerance through the utilization of mills and lathes.Reverse engineered existing products to produce new GE steam turbine replacement units to GE preferred vender specs.Utilized lean manufacturing process to reduce manufacturing cycle times and cost to build.Collaborated with both the sales and production teams to design new products that are inexpensive and easy to manufacture.Manage projects by holding engineering design meetings, communicating directly with customers/venders, documenting changes/test results/communications, and developing/editing project schedules (Gantt charts).

Designed, troubleshot, investigated, verified, and validated new and existing products, processes, and test equipment/tooling.Utilized SolidWorks design tools to documented new and existing custom test fixtures and tooling.Developed and executed verification and validation protocols in an FDA regulated environment.Prepared documentation such as Standard Operating Procedures, design specifications, and validation protocols.Participated in auditing, planning, and completing design specifications, and developing design standards all within an FDA QSR, design control, and ISO 13485 environments.

Charlotte, North Carolina, Us

Designed, documented, assembled, and identified problems with new automation cells, tooling, and fixtures.Designed a system of common platform automation assembles that utilized 75% common parts so parts could be made in bulk stocked, and reused at end of fixtures life, reducing cost and the turnaround time of the fixtures.Designed test fixtures to validate and verify that completed product satisfied all requirements and specifications.Created maintenance programs for equipment to reduce potential failures that could cause production downtime.Repaired, modified, documented, and reverse engineered existing automation cells and tooling fixtures.Implemented lean manufacturing/six sigma techniques to reduce production part cycle times and scrap.Optimized older equipment to increases its efficiency or make usable on new product production.Implemented new machining technologies, techniques and tooling reduce machine shop cycle times as much as 50%.Utilized design tools such as SolidWorks, ProE, Mastercam, and AutoCAD to design 3-D parts and assemblies.Programed Fadal CNC vertical milling centers and CNC lathes using Mastercam and/or M and G code.Collaborated with electrical engineers so that the mechanical and electronic components harmonize.Machined various prototype parts to tolerance through the utilization of mills, lathes, and Fadal CNC VMC’s.Collaborated with design engineers to help design prototype parts that were capable of being machined in-house.Programed Allen Bradley PLC’s, Robotic Arms using point click programing, and custom microprocessors using C.Used a manual Brown & Sharpe CMM to certify critical tolerances on important parts.Maintained parts list and delegated work to technicians and/or machinist to keep projects on schedule.Trained interns and engineers in the correct use of machine shop equipment and machine shop safety.

Maintained golf course, spray applications of fungicides, herbicides, and insecticidesOperated and maintained machinerySupervised fellow maintence employees

Blue Bell, Pa, Us

Utilized AutoCAD/Architectural Desktop to design, correct, and create mechanical, architectural, and electrical building plans (using X- references)Interpreted blue prints, sketches and red marksCalculated air duct size and egress distancesSet up and edited spec sheets. Created and maintained archive system for drawing

Bachelor Of Science, Mechanical Engineering

Associate In Engineering Science, Engineering