Johnny Hernandez
Lunenburg,USA
Summary
Manufacturing Engineer skilled in optimizing production processes and enhancing product quality. Led initiatives that improved first-pass yields and reduced rework costs, demonstrating strong analytical and problem-solving capabilities. Adept at implementing specialized manufacturing hardware and quality assurance protocols to ensure compliance and operational excellence.
Overview
30
30
years of professional experience
Work History
Project Engineer
NEO TECH
Westborough, MA
01.2024 - Current
- Led the technical execution and delivery of all hardware programs for a Tier-1 aerospace and defense prime contractor.
- Spearheaded technical relationship and production scaling, transforming account into largest revenue-generating customer at manufacturing site.
- Orchestrated and presented Product Readiness Reviews (PRRs) to client leadership, achieving 100% compliance for all product releases.
- Led procurement, design, and qualification of specialized manufacturing hardware, including stencils, SMT carriers, wave pallets, AOI/5DX carriers, and pressfit fixtures and tools.
- Developed equipment programs, including SMT thermal reflow profiling, selective solder and wave profiling, and automated CTI router programs for stress-free board depaneling.
Project Engineer
Podimetrics, Inc.
Somerville, MA
01.2022 - 01.2024
- Led the strategic manufacturing transition for the SmartMat medical device, successfully onboarding a new Contract Manufacturer (CM) while systematically ramping down operations and exiting the legacy facility.
- Qualified the new CM facility by executing IQ/OQ/PQ protocols to ensure compliance, and personally trained assembly line employees on quality standards and SmartMat assembly techniques.
- Minimized production downtime by providing technical support to CMs, troubleshooting equipment malfunctions and process bottlenecks to maintain continuous line operations.
- Chaired weekly partner meetings to resolve manufacturing defects, conduct root-cause failure analysis, and implement corrective actions (CAPA) to eliminate assembly failures.
- Managed engineering documentation and deployment by authoring standard process instructions, ECOs, and deviations, auditing BOMs, and designing custom tooling for commercial pilot release.
Project Engineer
NEO TECH
Westborough, MA
01.2020 - 10.2022
- Increased First Pass Yields by 30% percent by implementing “Real Time Feedback” process and generating and analyzing daily quality reports (Pivot table).
- Implemented cascading changeover process reducing machine downtime by two hours across all product lines.
- Performed root cause analysis and implemented corrective actions on quality issues to enhance overall product reliability.
- Developed post build reports to assess product quality and identify improvement areas.
- Generated process and maintenance procedures to standardize operations and ensure equipment functionality.
- Repair manufacturing equipment to ensure continuous operation.
- Design and order tooling to support manufacturing.
Project Engineer
Mack Technologies
Westford, MA
01.2019 - 06.2020
- Designed and procured specialized tooling and fixtures, including custom stencils, wave fixtures, router fixtures, press-fit fixtures, and SMT fixtures to support production.
- Established and configured mechanical assembly cells, sourcing all necessary equipment and custom tooling to optimize workflow layout.
- Programmed, maintained, and repaired automated manufacturing equipment to sustain high-throughput production.
- Reviewed and approved manufacturing Gerber files, ensuring design parameters met specifications prior to production launch.
- Authored data-driven quality reports for customers, highlighting key findings in weekly meetings and contributing to the development of post-build reviews and standard operating procedures.
Project Engineer
NEO TECH
Westborough, MA
01.2017 - 09.2019
- Increased First-Pass Yields by 30% by implementing a 'Real-Time Feedback' quality process and utilizing data-driven daily reports and pivot tables to identify line defects.
- Programmed and maintained automated equipment to enhance line throughput through SMT thermal reflow profiling, wave profiling, selective solder programs, and BGA rework profiling.
- Designed and procured specialized tooling—stencil, SMT, wave, AOI, Flying probe 5dx, and press-fit fixtures—while creating post-build and root-cause corrective action reports to address quality issues.
- Reduced machine downtime by two hours across all production lines through the development and deployment of a cascading changeover process.
Product Engineer
Cisco Systems
Boxborough, MA
01.2010 - 06.2017
- Established strong relationships with Hardware and Mechanical Engineering groups, ensuring high-quality release of new product PCB and mechanical designs.
- Create and implement Process Documentation, Engineering Change Orders, and Deviations using AGILE software.
- Chaired weekly meetings with contract manufacturer to address Mfg/Quality issues, track quality alerts, and review deviations, corrective actions, and failure analysis.
- Technical member of Quality Improvement and Defect Reduction Teams. Evaluated factory and field failures with emphasis on implementing improvement and solutions.
- Developed rework documentation, procured materials, negotiated pricing and delivery expectations for Sub Contract repair facilities.
- Developed assembling instructions for new product and trained contract manufacturers.
- Coordinated material change notices (MCNs) to manage product specifications and ensure compliance with engineering standards.
- Transfer product from Plexus in Boise, Idaho to Flextronics In Austin, TX and ultimately to Flextronics in Guadalajara, Mexico.
Manufacturing Engineer
Starent Networks
Tewksbury, MA
01.2009 - 01.2010
- Collaborated with design engineering to integrate new part and process technologies.
- Created and implemented release and process documentation, engineering change orders, and deviations using AGILE software.
- Reviewed all BOMs, documentation and packaging prior to pilot release.
- Created and delivered in-house rework instructions and conducted training for operators on rework.
- Developed product conversion instructions that streamlined processes for low demand products.
- Maintain inventory for all rework components and components to be sent out for failure analysis.
- Supported integration efforts during Cisco acquisition
Senior Manufacturing Engineering Process Technician
Plexus Corp
Ayer, MA
01.1997 - 01.2009
- Trained and supervised operators on processes and equipment utilization to enhance operational efficiency.
- Directed New Product Introduction. (NPI), process development.
- Created and Implemented process procedures.
- Implement process changes to improve assembly cycle time and quality.
- Establish reflow profiles, wave profiles, and BGA Rework profiles.
- Performed corrective actions on customer complaints and non-conforming production, implementing improvements and rework directions per IPC Quality Standards.
- Compiled and submitted weekly line downtime reports to management, facilitating informed decision-making.
- Interviewed and screened candidates for SMT operator position.
- Perform Maintenance on all Equipment per Schedule.
Education
Bachelor of Science - Business Administration and Management
Becker College
Worcester, MassachusettsSkills
- PCBA Thermal Profiling
- Quality Assurance Tools
- CAD Design
- SolidWorks
- Technical support
- Detailed analysis
- Root cause analysis
- Manufacturing documentation
- Problem solving
- Relationship management
- Technical support
- Quality Assurance: PCB
inspection, solder inspection,
Component ID, per IPC-A-610 and
J-STD-001
Equipment Validation: IQ, OQ, PQ
Process Development
Equipment Background
- Juki
- Ekra
- Electrovert
- DEK
- Mydata
- Omni Flo
- Soltec
- Heller
- GSM
- ERSA Selective Wave
- Ionograph
- MPM
- KohYoung
- Pillar House
- CTI Router
- Vapor Phase
- TE MEP-10T MKII Press-fit
- Agilent 5DX
Timeline
Project Engineer
NEO TECH
01.2024 - Current
Project Engineer
Podimetrics, Inc.
01.2022 - 01.2024
Project Engineer
NEO TECH
01.2020 - 10.2022
Project Engineer
Mack Technologies
01.2019 - 06.2020
Project Engineer
NEO TECH
01.2017 - 09.2019
Product Engineer
Cisco Systems
01.2010 - 06.2017
Manufacturing Engineer
Starent Networks
01.2009 - 01.2010
Senior Manufacturing Engineering Process Technician
Plexus Corp
01.1997 - 01.2009
Bachelor of Science - Business Administration and Management
Becker College