Melanie Johnson Email and Phone Number
Corvallis, Oregon, United States
Melanie Johnson's Location
Benton County, Oregon, United States, United States
About Melanie Johnson
With over a decade of experience in process engineering, I've honed my skills in managing cross-functional teams and driving projects to enhance manufacturing processes and quality systems. I've demonstrated expertise in SPC (Statistical Process Control), quality systems, continuous improvement, project management, and lean manufacturing methodologies, delivering significant savings and improving workflow in the inkjet and semiconductor manufacturing industries. My recent role at HP has been instrumental in furthering this journey, where I led initiatives such as qualifying analytical tools, transferring technology, and implementing process FMEA (Failure Mode and Effects Analysis).In my recent roles at RLA Engineering LLC and Insight Global, I furthered my expertise in mechanical tooling, process development, and senior process engineering. Notably, I managed SPC implementation for inkjet cartridge manufacturing and led projects to qualify new tools and slurry, resulting in substantial cost savings.During my tenure at Viper Northwest, I served as NPI (New Product Introduction) Manager, Engineering Manager, and Quality Engineer overseeing teams, driving process improvements, and managing customer interactions. My experience includes leading cross-functional teams, redesigning processes, and developing KPI (Key Performance Indicators) dashboards to drive performance.My early career spans roles in metrology process development, where I managed the procurement and qualification of advanced metrology tools and led teams to overhaul software for improved reliability. I've always been passionate about driving efficiency and excellence in manufacturing processes.With a Master's degree in Physics from Oregon State University and a Bachelor's degree from the University of Nevada, Las Vegas, I bring a strong technical foundation to my work. I am adept at leveraging data analysis, project management, and problem-solving skills to achieve organizational goals.I'm excited to bring my expertise to new challenges and collaborate with teams dedicated to innovation and excellence in manufacturing. Let's connect and explore how we can drive success together.
Melanie Johnson's Current Company Details
Inpria
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Process Engineer | Manufacturing Process Improvement, Measurement and Quality Systems
Corvallis, Oregon, United States
- Website:
- inpria.com
- Employees:
- 97
Melanie Johnson Work Experience Details
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InpriaCorvallis, Oregon, United States
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Process Engineering SpecialistHp Apr 2022 - Jun 2024Palo Alto, Ca, Uso Process engineer for ink manufacturing. Support twenty-three analytical tools used for QC (Quality Control) process, that measure parameters including: - particle size - particle count - viscosity - surface tension - density - light absorbance spectrum (UV-Vis) - pH - conductivity - percent solidso Qualified nine tools for production use.o Supported transfer of dispersion milling technology from Puerto Rico to Corvallis and transition to business continuity planning. o Established and led team to create and maintain process FMEA. o Led team to create safety fixture, allowing production to fill both small and large containers from the same build without splashing or excessive foaming. o Created SPC charts for quality tool verification data.o Improved pH probe lifespan by more than 5X.o Led project to organize area open house and inventory and locate equipment sent from Puerto Rico site.o Set up and documented processes to provide GHS (Globally Harmonized System) compliant shipping labels.o Led teams (production, engineering, and supply chain) through scale-up builds to transition products from R&D to manufacturing and to provide larger quantities of mixed chemicals for R&D efforts.o Backup bio-abatement engineer.o Auditor for internal audit. -
Mechanical Tooling And Process Engineer (Contract Role At Hp Inc.)Rla Engineering Llc Nov 2020 - Apr 2022Vancouver, Washington, Uso Spearheaded SPC for inkjet cartridge manufacturing line, enabling rapid issue identification during development, release to manufacturing, and overseas transfer.o Project manager (scoping, scheduling, tracking and risk management), and technical leader (writing SQL queries, data analysis in JMP and Excel, SPC chart creation, training development and presentation) to implement SPC for an inkjet cartridge manufacturing line used for production, prototype and NPI. o Managed quality dashboard and quality management systems (QMS) compliance for cartridge manufacturing during development of the new technology product. o Swing shift engineering support for pen body assembly processes. o Tool process owner for foam stuff process. -
Senior Process Engineer (Contract Role At Hp Inc.)Insight Global Oct 2018 - Oct 2020Atlanta, Georgia, Uso Supported and developed saw, CMP (Chemical Mechanical Planarization) and grind processes for piezo-electric and thermal ink jet product lines.o Led panel carrier development and logistics efforts for packaging fab. o Integrated development, supply and long-term systems for panel carrier for new packaging area. o Qualified new CMP tool for piezo products to replace obsolete, unsupported tool. The new tool and processes also improved workflow, reduced time and tool risk from CMP tool changeover, and reduced product risk from wafer breakage and other scrap.o Co-lead project to qualify new slurry, resulting in annual savings of 25%.o Collaborated across multiple parts of the organization for two weeks to analyze issues with saw can supply. Interviewed stakeholders, developed a plan to resolve ongoing issues and brought the stakeholders together to finish the plan and assign owners. This resulted in an ample supply for current needs without purchasing additional carriers and provided visibility to actual needs when products ramp in the future.o Coordinated an international project to reduce types of saw tape used in production. Resulted in 15% reduction in local production saw tape inventory items.o In first 15 days - identified, shepherded through change management review and implemented an opportunity for reduced operator interaction without a negative impact on product quality.o Mentored new engineer completing first equipment purchase project.o Co-managed $150K consumables inventory.o Created documents, including specifications, operations guides, and additional pages on data queries for new employee training and video instructions to maintain knowledge base for very infrequent processes.o Documented panel carrier designs with Creo. -
Npi ManagerViper Northwest Apr 2017 - Jul 2018Albany, Oregon, Uso Led NPI (New Product Introduction) department in build to print manufacturing company. - NPI quoting team reviewed customer sketches, drawings and specifications to provide quotes. - NPI engineering team converted customer sketches to drawings, created manufacturing instructions used to make customer design and resolved issues arising during product roll out. - Work was fast-paced – introducing approximately 20 new products per week.o Day-to-day interaction and management of engineering and quoting teams including hiring, performance plans and reviews, allocating resources, prioritizing tasks and projects, coaching and career development, mentoring, recognizing outstanding performance and correcting poor performance. o Led cross-functional team (quoting, accounting & compliance) in redesign of new customer process, reducing financial and export compliance risk while reducing time lost to unproductive quotes.o Determined work center equipment valuations to enable accurate evaluation of quote profitability.o Participated in development of brand strategy and customer experience improvement.o Worked with customers to develop appropriate expectations and specifications, including negotiating specifications that were not manufacturable.o Performed administrative and oversight functions in approving proposals, expenditures and certain customer communications as well as policy enforcement. o As part of a smaller team, created KPI (Key Performance Indicators) dashboards for the executive and management teams, developing metrics that were relevant, easily understood and actionable.o Created reports to pull data from ERP and SharePoint systems to provide meaningful visual information about the department and overall business conditions.o Developed and implemented department annual and quarterly plans. -
Engineering ManagerViper Northwest Aug 2015 - Mar 2017Albany, Oregon, Uso Managed a team of eight engineers and technical support individuals.o Led engineering team to redesign the work instruction creation process leading to a doubling of capacity and a simultaneous reduction in errors. - Changes included creating a SharePoint log to streamline work tracking and assignment and creating documentation and tools to prevent errors and interruptions. - Results included a greater than 90% reduction in interruptions.o Day-to-day interaction and management of engineering team including: including hiring, setting and monitoring of annual performance plans, allocating resources, prioritizing tasks and projects, coaching and career development, formal performance reviews, informal mentorship and training, recognizing outstanding performance and correcting poor performance. o Developed metrics to measure efficiency and effectiveness.o Led a team (engineering, purchasing, facilities, and vendors) to purchase and install a cleanroom, allowing successful bid and manufacture of a new product line. o Created the manufacturing engineering training, structure and processes needed to provide engineering supported process improvement and successful manufacture of higher volume products. o Established a "war room" process for pulling together internal experts to quickly and accurately respond to the most challenging customer quote requests. o Performed administrative and oversight functions in approving proposals, expenditures and certain customer communications as well as policy enforcement.
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Quality EngineerViper Northwest Aug 2014 - Nov 2015Albany, Oregon, Uso Primary interface with largest customer's quality department. Led internal efforts to conform to customer quality requirements.o Analyzed opportunities, developed a strategy and worked collaboratively with other functional areas to improve the quality scorecard from our primary customer. Score improved from red to green in just over a year, although it had been in the red for over a year when I was hired.o Led a team of three technical writers, meet primary customer's demand for extensive process documentation. Included hiring and laying off temporary employees needed for three month project.o Worked with planning, production and document control to create a self-maintaining system for documenting product specific processes. o Investigated customer quality complaints, led Root Cause/Corrective Action (RCCA) process and worked with internal departments, suppliers and the customer to resolve.o Provided manufacturing engineering support as needed.o Participated in teams to establish export compliance rules, evaluate business continuity risks and measure employee engagement.o Audited and trained suppliers in quality requirements of Viper and Viper's customers.
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Parenting SabbaticalN/A Jun 2005 - Aug 2014
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ConsultantMelanie T Johnson Consulting 2005 - 2010Projects included: o Suggesting a plan to setup and implement oceanographic instrument calibration systems. o Providing expert advice on NIST traceability. o Set-up, calibration and training on Laser Scanning Microscope (LSM.) o Designing and implementing improvements to quality tracking system.
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Metrology Project EngineerHp 2002 - 2005Palo Alto, Ca, Uso Responsible for procurement and start-up of production capable LSM and FIB/SEM and new processes to measure, characterize and control critical polymer features of development phase Thermal InkJet MEMS products.o Led a cross functional team to select, purchase, install, characterize and release a $3.5 million Focused Ion Beam / Scanning Electron Microscope (FIB/SEM) metrology tool. o Managed multiple vendors and a cross-functional team to coordinate the development, purchase and qualification of a $1.3M first-of-a-kind production-capable automated laser scanning microscope (LSM,) keeping the project on track and within two months of original schedule while implementing a process redesign. o Documented and presented complex geometric specifications that were clearly understood by technical and non-technical participants in a FIB/SEM purchase negotiation meeting. This enabled process control critical to the development and release of a new product line.
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Metrology Process Development EngineerHp 1999 - 2002Palo Alto, Ca, Uso Responsible for sustaining and developing optical and film thickness metrology processes on polymer layers in MEMS wafer fab facility. Owner of measurement processes supporting the production of polymer layers.o Mobilized cross-functional, multicultural team to convince vendor to overhaul tool control software, resulting in a 75% decrease in incident reports and a 10X improvement in worldwide process stability.- Completed four months after initiating tool ownership although it had been unresolved for two years prior to my arrival. - Simultaneously coordinated a tool matching project with the same vendor, resulting in improved data and overseas technology transfer.o Promoted indirect measurement across organizational boundaries, convincing reluctant internal customers to champion changes that improved metrology reliability (up to 50X.) o Led a multinational team to match tool calibration and product measurements worldwide.o Developed a non-destructive optical metrology technique, enabling more frequent metrology for improved process control. First event captured resulted in savings greater than the project cost (~$700K.)o Used gauge R&R and visual descriptions of product architecture to promote an indirect measurement across organizational boundaries, convincing reluctant product engineers to not only accept, but to press for change, thus simplifying my process, while simultaneously improving their data (up to 50X for some products.)o Developed and documented processes and statistical process control.o Worked with data team to simplify process control database structure.o Performed DOEs.o Developed and specified strategies for metrology routines.
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Back End Process EngineerJohnson Matthey Electronics 1997 - 1999London, Greater London, Gbo Responsible for supporting back end processes, including cleaning, testing, quality assurance, cleanroom and packaging.o Guided machinists through troubleshooting processes to determine causes of product defects thereby resolving increased machine tool breakage and high rework rates.o Developed an automated copper cleaning process which improved sputtering target cleanliness and reduced risk of oxidation en route to customer. o Partnered with another engineer to reestablish ultrasonic measurement process, including standards, procedures and documentation stabilizing results and eliminating unneeded remeasurement.o Performed both standard and Taguchi DOEs.o Designed fixtures.o Developed, implemented and documented processes.
Melanie Johnson Education Details
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Oregon State UniversityPhysics -
University Of Nevada, Las VegasPhysics
Frequently Asked Questions about Melanie Johnson
What company does Melanie Johnson work for?
Melanie Johnson works for Inpria
What is Melanie Johnson's role at the current company?
Melanie Johnson's current role is Process Engineer | Manufacturing Process Improvement, Measurement and Quality Systems.
What schools did Melanie Johnson attend?
Melanie Johnson attended Oregon State University, University Of Nevada, Las Vegas.
Who are Melanie Johnson's colleagues?
Melanie Johnson's colleagues are Dom Smiddy, Lauren Mcquade, Bryce Benson, Tanner Hankinson, Jonas Harrison-Beard, Nick Humphreys, Jérôme Van Canneyt.
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