Karl Johnson Email & Phone Number

Stamford, Ct, Us

Morris Ct

Branford, Connecticut, United States

• Reduced lead-time by 48 hours (50% of build time) for multiple sensors by optimizing BOM (Bill of Material) to replace timely potting operations with equivalently effective insulating fiberglass material.• Increased production yield from 60% to 100% for a new product by redesigning a Welding alignment tool.• Improved on-time-delivery from 0% to 80% by project managing all NPI sensor builds and by establishing workflows with Supply Chain, Scheduling, Stockroom, Production, Quality and shipping departments.• Supported financial analysts and production forecasting by conducting time studies, creating engineering Masters, accurately linking finance resources to manufacturing operations and maintaining BOM changes.• Improved plant operations by creating controls around PFMEA designated risks, optimizing quality inspections, streamlining manufacturing instructions, and automating critical manufacturing KPIs.

• Increased solar revenue by 2% by reprioritizing repair scheduling using statistical process control (SPC) and introduced real-time energy production and return on investment (ROI) reporting.• Recovered expenses by conducting a root cause analysis of faulty equipment that led to a successful insurance claim and speedy corrective action and issue resolution.• Reduced outside service expenses overseeing the RFQ process for a third party facility maintenance contractor and presented my recommendations, approved by management.• Eliminated FTE by automating manual data entry tasks; delinquency reporting for Lease, Loan and Power Purchase Agreement customers; and selecting Most Effective Technology (MET) software for tracking financial covenants.• Reduced weeks of operational down time by optimizing and managing an inventory of Solar Photo Voltaic equipment allowing for quick response to equipment failure.

• Created and presented interactive SolidWorks and MakerBot software lessons to a section of 40 students.• Responsible for oversight of four other teaching assistants.• Evaluated and graded students’ progress and projects throughout the semester.• Managed the MEM 3D printer lab and maintained, diagnosed, and repaired 3D printers.

Bristol, Ct

• Reduced costs by eliminating use of third party foundries for cast products by developing a time study-based return on investment analysis and presenting to management.• Decreased Factory Cycle Time (FC) by 30min/part (16% total creation) through part consolidation simplifying the bill of materials and simplifying assembly and reducing total labor fabrication time.• Eliminated FTE by creating Standard Manufacturing Instructions (SMI) and automating and optimizing the machining commands and processes for line and machine technicians.• Coordinated new process implementation strategies with engineering, fabrication, and product development departments to migrate the production of aluminum vibratory bowls from being outsourced (cast) to machined from billet in-house. • Completed projects on time and within budget and ensured the deliverables were superior to previous products.• Improved product manufacturability and line productivity by managing and supervising non-organized production workers learning manufacturing process.• Increased the output of vibratory bowls by eliminating the supplier bottlenecks.

Farmington Ct

• Eliminated FTE by creating and automating CNC machining command programs in AutoCad from engineering drawings • Reduced processing time by 900min/shift (1min/part at 900parts/shift) by rearranging the production line in order to reduce unnecessary motion. • Prepared a study for management by surveying organized (unionized) production line workers with regards to areas for improvement and strategized process improvements with Engineering and Manufacturing, which led to reduced over-processing, minimized waiting and reassigned underutilized talent.• Created Standard Operating Procedures (SOP) for assembly and machining processes. • Improved factory efficiency by 5-10% by assisting with a shop floor layout redesign which replaced two obsolete computer-aided manufacturing (CAM) stations with a gas powered laser CAM station.• Conducted 5-S safety audits for all work centers in the factory to ensure compliance with OSHA standards.