Sarah Johnson Email & Phone Number

Lafayette, Colorado, United States

Also held positions as Process Development Manager & Process EngineerLead Quality, Regulatory, Safety, Process Engineering, New Product Introduction (NPI), Facilities, Equipment Maintenance, and Training functions. Collaborate with Sales, Procurement, Production, Warehouse, and Design Engineering to develop and monitor regulatory compliance processes, key metrics, and goals. Selected Impacts:• Spearheaded effort to achieve AS9100 certification in just 6 months, accomplished with only 4 minor non-conformance reports (NCR’s) and while also maintaining ISO9001 and ISO13485. • Additionally, attained zero non-conformances and perfect scores (PEAR) for first AS9100 surveillance audit.• Supported company’s ability to take on additional projects via creation and launch of NPI stage gate process.• For the first time in 3 years, attained profitability on production line with excessive labor expenses. Teamed with 10 operators to identify 47 time-saving recommendations, prioritized ideas, and instituted improvements. Effort also included educating operations on lean principles and correction of WIP and quality errors.• Expanded capabilities of technicians and Process / Quality Engineers via development and delivery of trainings on FMEA, lean, Cpk studies, root cause analysis, designed experiments, Gage R&R, and applied statistics.• Collaborated with engineers, technicians, and operators to deploy Lean Six Sigma initiatives. Results:• Reduced Product R2 labor/unit from 4.26 to 3.3 minutes with a capital expenditure of $8K that saves $82K/year.• Increased throughput of Product R3 by 20% with lean manufacturing tools only, achieving customer OTD request. • Improved Product N production yields from the predicted <90% to >97% via execution of applied statistics and Cpk study.• Lowered validated warranty return rate from 1.6% in 2017, to 0.7% in 2019, to .02% in 2021• Cut Product Z labor variance by 300% via lean project implementation.

Frederick, Co

Headed improvement and documentation of Value Stream Mapping (VSM) MRP processes including materials management, purchasing, inventory control, production, shipping, and receiving. Served as Subject Matter Expert (SME) resource and mentor for lean and Six Sigma concepts.Selected Impacts:• Reduced cycle time by 23% via workstation re-design on bottleneck process.• Increased storage space by 21%, improved visual management, and decreased walking time with no cash outlay via lean warehouse reorganization. • Led initiative to reduce welding reworks from 30% to <5% and capture gains in standardized work instructions.

Flower Mound, Tx

Interior Design and Realty StagingManaged design projects and improved operations for sourcing, data collection, marketing, and accounting. Interfaced with clients to define requirements, manage accounts, and resolve issues. Selected Impacts:• Raised profit margin on goods 30% via institution of new sourcing process.• Doubled sales from 2010 to 2011 and sold company for a profit in 2012.

Irving, Tx

Also held positions of Wafer Fab Engineering Manager, Process Engineer, Quality EngineerFabricator of discrete semiconductor devices in a high-volume manufacturing environmentSpearheaded division-wide deployment of Six Sigma methods. Developed business processes and infrastructure and wrote procedures to govern projects and install reporting structure. Assessed opportunities and determined which projects to pursue based on ROI. Coordinated across US and Mexico sites to communicate and systemize improvements. As Process Engineering Manager, owned entire manufacturing process and product quality of 4+ million parts/day. Delivered consistent new cost reductions/yield improvements from fab engineering group.Selected Impacts:• Instituted training system for 20+ engineers and technicians to become Six Sigma and lean certified; led Green Belt training for technical and non-technical staff.• Saved $1.2 million annually via major yield diffusion process project and recouped $300k/yr. by converting highest volume product to higher yielding process.• Cut scrap in finished product from 3% to 1.7% by re-characterizing key processes.

Master Of Science (Ms), Industrial Engineering

Bachelor Of Science (Bs), Industrial Engineering