Zachary Johnson

• On Contract with Dillon Automation as Lead Robot/Vision Engineer
• Established strong working relationships with clients through exceptional communication skills, fostering trust and collaboration.
• Achieved successful project outcomes by maintaining accurate documentation and meeting strict deadlines.

• GM Direct. Engine and Transmission, T1XX2 RETM
• Liberty Robotics Vision Guided Robots.
• Carried Bolt Fastening Gun, Torque Checked.
• Carried Telesis Pin Stamp for Vin # Etching
• Material Handling
• 7th axis RTU, 6 Racks, 48 separate Transmission pick locations.
• 2 Racks with 6 different engine models.
• Developed software tools to simplify robot programming tasks, increasing efficiency of overall design process.

• Started out new at Bin Picking but in a short time I became on of Kuka's top Bin Picking Specialist proving myself to Kuka's Lead Programmers. Combining all my previous robot knowledge and vision experience helped me catch on very quickly.
• I learned a vast amount about Bin Picking applications while at Kuka. Spending most of my time in the (R&D) department at the Kuka Tank Plant. Customer would send Future or Existing Part Models to Test with Bin Picking Applications. After getting the Robot and end effector set I would program the vision system picks and programs. I would then run a “Part Evaluation Test” to determine whether the part and EOAT could be used in production. Different pick solutions or end effector designs were sometimes required to Pass the Part and EOAT. A 98% Success Rate was required to pass part, ensuring it was ready to be sent into the field for production.

GM Direct Work (on Contract with Kuka)

• Lake Orion, Michigan 2024
• KA 045 Photoneo Bin Pick using Roller racks…
• AD Zone I programmed the Keyence Bin Picking Robots on 7th Axis slides while out at Kuka Livonia Plant.

• Fort Wayne, Indiana during 4th of July shut down 2024.
• BA Zone. This was the zone I set up and programmed from start to finish. I also worked on the other 3 BA Zones but I did not do the installation.
• DD Zone. Also worked on the other DD Zones while on Kuka's floor but I did not do the installation.

• Lansing, Michigan 2024
• Lead Programmer
• CN Zone
• Mag Switch Smart Mag, Pneumatic Magnets, and suction cups.
• Keyence Vision Bin Bicking
• PhotoNeo Vision Bin Picking
• Matrox Vision used for 2D Offset and Pass or Fail Part Inspection

• Fort Wayne, Indiana during Christmas shut down 2023.
• AG Zone. Keyence Vision Bin Picking with Matrox 2D Offset for drops.
• Designed custom robotic systems, meeting unique client specifications and industry requirements.

• 3 Bin Pick Training Cells at the GM Tech Center.
  Lead Programmer from start to finish. Started at Kuka Sterling Heights (KSH), shipped and installed to GM Tech Center Building B.
  Worked with GM team to help setup the class and training program for GM Employees to learn Bin Picking with Keyence and Photoneo Vision Systems.
  Each Cell has 1 Keyence Camera, 1 Photoneo Scanner, 1 Matrox Camera, and 1 Material handling Fanuc Robot with E20 MagSwitch Smart magnet.

• Gestamp. Lapeer, Michigan->GM B Pillar. BT1CC. EV Silverado.
• Created weld programs sequencing and robot interference zones to improve cycle times.
• ABB/Fanuc Robotics Engineer
• Spot Welding
• Mig Welding
• Projection Nut Welding
• Material Handling

• Midway Products Group->Ford Mustang
• LH/RH body sides/hydroformed tubes with hexagon laser cut holes.
• IR vision. Installed/Calibrated. The IR vision was used for Pedestal RivNut drills.
• Pedestal RivNut drills.
• Spot Welding Carried/Pedestal
• Mig Welding
• Robot mounted Laser Welding
• Optimized robot performance for increased productivity with advanced programming techniques.

• Promoted to Lead Robotics Engineer, overseeing up to 6 programmers at a time.
• Managed required work hours on the project, work performance, and cell efficiency.
• Created a pro-active and efficient work environment with the robotics team on projects I was overseeing.
• Interacted with customers directly and developed matured customer relationship skills.

• Martinea WS floor pan project->Stellantis/Jeep Wagoneer
• Worked directly with MRE to produce new Fanuc standard with customers, led a team of 10 programmers to launch this project. (60 robots, 2 models) all build dates and cycle time requirements met on time and quality.
• Established functional standard with recovery for applications including: SCA Seal, Coherix Vision, Bosch Spot Welding, 7th axis RTU, BTM clinch Nut
• Ford Dearborn.> Mustang
• Fanuc robots, applications included ATI, Henrob riveting and SCA sealer units (5 models).
• Worked hand in hand with Ford pre-production team to establish safe and functional model select.
• Established functional sealer swirl nozzle procedure and trained Ford personnel.
• Martinea. Coordinated Motion Trailer Hitch Cell->Stellantis/RAM
• Led coordinated motion cell with 2 separate dual arm coordinated motion robots.
• Mig Welding/Material Handling.
• Martinea did not have a functional standard for dual arm coordinated motion, a standard was developed with my extensive research and input.
• Martinea. Floor Pan in Cordon, Indiana.->Ford/Lincoln
• 50 robot systems, lead team of up to 5 programmers from startup to buyoff
• Cycle time met on time and exceeded expectations.
• Weld technician with Bosch weld timers.

• Martinea T1XX program>GM
• I gained vast experience as a robot programmer working on the systems I previously built, also learning from the best in the industry.

• Worked with industry experts building, piping, and wiring full automation systems

• Ran 3 axis CNC machines
• Gained in depth knowledge of machine set up, maintenance, Crane and Hi-Lo safety. Precision machining processes and value in professional of a skilled trade.

• Cut different Materials (Felts/Leather/Plastics/Foams/Rubber) to specified shapes/sizes for Customer order.
• Loaded/Unloaded Trucks with Hi-Lo