Sean Johnston

Process Development Engineer - Assembly Systems Group (Current Role)

• Commissioning equipment upgrades and supporting tooling and test rig transfers, collaborating with cross-functional teams to ensure manufacturing readiness for smooth integration into production.
• Conducting root cause analysis to troubleshoot and resolve test/assembly issues – often under production pressure to maintain output and quality.
• Integrating LabVIEW software resolutions to support our production lines.
• Actively involved in continuous improvements initiatives.

Process Development Engineer - Assembly Systems Group (12 months)

• Procured and duplicated a process for one of Renishaw’s most profitable product ‘Resolute’ to scale manufacturing capacity.
• Reconstructed manufacturing test rig, gaining knowledge in PLC electrical wiring and proficiency in interpreting Zuken wiring and Visio system schematics.
• Developed an interactive production dashboard to provide stakeholders with a live view of production breakdowns (Power BI / SQL / SharePoint).
• Designed and remodelled assembly rig parts through NX / Teamcenter.
• Authored build documentation and ensured compliance with safety standards.
• Supported Windows 10 integration across production systems, mitigating software risks and utilising production down time.

Process Improvement Engineer - Resolute Current Products Engineering Group (6 months)

• Led the design and integration of a process improvement to step lock a process in production, providing stakeholders guarantee that the process was being carried out.
• Strategically selected methodology to reduce cycle time and meet target margins of the new process.
• Resolved mechanical issues/breakdowns in production and provided approval recommendations effectively.
• Tended to support production, operators and management, with issues/concerns and provide suitable resolution for all parties.
• Investigated incoming external defective units. Through conducting research, and incremental testing methods to determine if the defective units would affect the product in a cost-effective manner.
• Tracked and flagged at-risk products, implementing containment and corrective actions.
• Provided training and support to production staff, aiding a culture for continuous improvement.
• Attended weekly COPQ sessions between production and engineering, where we assessed trends, determining root causes and advised steps to implement to improve quality.
• Routinely carried out Preventive Maintenance Inspections.

Project Engineer (Hybrid/Systems Placement) - Assembly Systems Group - Projects (6 months)

• Assisted project engineers in Renishaw’s biggest manufacturing investment for the factory of the future initiative (> £1.2 million).
• Collaborated in multiple areas of the business building strong relationships with Logistics(Warehouse), IT and Security.
• Developed new process flows for warehouse operations and supported PFMEA analysis.
• Conducted data analysis for predictions and understanding challenge ahead and updating relative stakeholders on relevant info, utilising SQL, Excel and Power BI to do so.
• Negotiated layouts and temporary space to keep warehouse in operation. Utilising Solid Edge to convey layout ideas.
• Chaired meetings and delivered weekly updates to address issues, solve problems and discuss areas for improvement. Using concise visually informative PowerPoint to engage stakeholders with.
• Designed tooling upgrade for assembly rig and supported the design of a heavy-duty support carrier for an automated project.
• Supported the creation of the manufacturing divisions knowledge sharing platform.

Outline

Working with international students from all over Europe to generate a proposal and strategy to improve traffic in Vilanova.

• Planned the project overview by generating a Gantt Chart to provide realistic goals and clarity of the project's vision.
• Managed the project into smaller achievable goals via use of Kanban board.
• Adapted to remotely working online via Google Meet whilst travel restrictions were imposed and managed to move country in a short period under the circumstances.
• Allocated roles to suitable team members.
• Supported team members.
• Acquired professional advice from supervisors.
• Drove ongoing performance improvement, managing individual development plans for my colleagues.
• Set up weekly team meetings with supervisors to discuss the project's progression (expressing ideas via presentation.)

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Key Achievements

• Successfully managed and delivered project as team leader.

Outline

The job entailed going door-to-door to encourage people to sign-up to support charities long-term by donating monthly to help the charities reach their goals.

• Supported team leader in training a team of newcomers on the job to become consistent at meeting and exceeding fundraising goals.
• Developed new improvement initiatives that increased lifetime value of donors.
• Utilised software to design persuasive proposals achieving a higher conversion rate.
• Team motivator

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Key Achievements

• Recognition was received by the manager that there was potential to be trained for the role of a team leader.
• Successfully managed to help raise a substantial sum for RNIB & NDCS.