Matthew Johnson, PMP, CSSBB

Experience

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  Lau Fan

  Jan 2001 - Jan 2008

  Project Engineer

  • Worked closely with OEM customers to develop customer specific products such as stackable direct drive plenum fans and low noise / high efficiency propeller blade for use in residential air conditioners.• Developed a line of commercial direct drive plenum fans capable of achieving performance equal to much higher cost industrial fans. Design tasks included impeller design ranging from 10 to 40 inches and support structures tuned to eliminate natural frequencies in the operating range.• Lead new product development team that included drafters, manufacturing engineers and test lab teammates.• Create detailed solid and sheet metal models with Pro/Engineer.• Analyze strength and modal characteristics of design concepts through hand calculations and finite element analysis with the aid of ANSYS and Pro/Mechanica.• Develop test procedures to evaluate new and existing products.• Aid customers with the selection of air movement equipment specific to their application. Show less

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  Midmark Corporation

  Aug 2008 - May 2013

  Design Engineer

  Led development of jury-based sound preference model to evaluate sound emitted by exam and procedure tables as a custom sound/vibration data acquisition system. Developed detailed models and drawings of components and assemblies using Pro/Engineer and PTC Creo and Windchill PLM software.Conduct finite element analysis using Pro/Mechanica and mechanism design using Pro/Mechanism.Midmark 630 HUMANFORM Development Teamo Developed foot section with powered extension to support the legs of average height patients with an additional push button extension feature to comfortably support taller patients.o Mapped mechanical efficiencies through foot section mechanism to define actuator torque requirements through range of motion. This would later be used as the basis for firmware logic to limit the amount of current being drawn from the wall to 12 amps while operating four mechanisms simultaneously.o Implemented active sensing system to protect both patient and health care provider from harm should the foot section impact an obstruction during downward powered motion.o Designed second generation rotation base assembly. Improvements include top down product assembly, modular design to accommodate future features, suppression of locking mechanism noise, reduced weight and cost.Ritter 253 LED Light Development Teamo Responsible for light head assembly and optic quality.o Challenges include hidden fasteners, snap finger design, feel of focus mechanism, light intensity, color temperature, uniformity and LED selection to ensure proper tissue color rendering.o Implemented sorting procedure to verify LED color bin sorting and intensity.o Color spectrum filter to dial in optimal color temperature.o Micro-optic diffuser to improve uniformity of light output. Show less

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  Hartzell Air Movement

  May 2013 - Mar 2014

  Project Engineer

  Supported OEM sales with custom equipment design and selection.Worked with manufacturing to identify process deficiencies and implement control plans for locomotive brake cooling fan line to include machining test fixtures, assembly tooling and trim balance.Finite element analysis using SolidWorks and COSMOS to evaluate designs for modal response and strength.

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  Henny Penny

  Mar 2014 - Oct 2020

  Serve as mechanical lead for new product development projects and provide direct guidance to multiple engineers and designers.Lead product definition requirement development via collaboration with product management, service and engineering. Utilize tools such as Teams, Jira, Confluence, Gitlab and Smart Sheets.Lead DFMEA development activity.Control system architectural lead responsible for facilitating multi-discipline design and documentation of electro-mechanical system to include.o CAN bus communication, hardware and softwareo Logic flow definition and documentation utilizing Visio.o Firmware logic requirementso User interface designo Component selection and heat mitigationo Error handling and prioritizationo Troubleshooting and service considerationso Agency design considerations for UL and CE approvalMentor interns and engineers in the follow topics with two interns being hiring on as engineers after graduation.o Tolerancing and manufacturabilityo Test methodologyo System designo Data analysiso Model and drawing structureo Agency design considerationsHelped revise new product development process by defining design review process requirements.Developed next generation pressure fryer.o Pressure vessel design to meet both ASME and PED requirementso Lid safety lock mechanism that activates when pressure is present in vessel to ensure operator does not open lid under pressure.o Finite element analysis on pressure vessel and various lid lock mechanism components using ANSYS.Aid in the creation of development schedule and coordination with various supporting departments using Smart Sheets.Implemented top level and down assembly prints and controlled models for new products using NX and TeamCenter. Show less Project lead responsible for development of project schedules, communication and coordination of development activities across multiple departments using Smart Sheets and Microsoft Project.Implemented several design changes on low oil volume fryers to improve robustness of unit against environmental and user abuse resulting in approximately $500k reduction in annual warranty claim expenditures. Improvements include.o Gas burner, draft blower capable of digesting debris and oil vapor laden air without performance degradation. Achieved agency combustion validation for high altitude as well as domestic and international gas types.o Improved blower motor cooling to allow operation in ambient environments up to 210°F.o Redesigned limit switch mechanisms to utilize plunger style switches rather than lever arm switches and incorporated robust mechanism adjustment to eliminate the need for adjustment in the field.o Improved cycle life of filtration crumb basket against being slammed on trash can to clear debris from 1000 to 11,000 cycles.o Filter pan redesigned to handle being dropped onto concrete repeatedly.Worked with manufacturing on design, process and test protocols to improve first time through metrics.Studied cause of nuisance high limit events responsible for fryer down time. Resulting in system improvements to allow an additional control input and logic changes to the heat control algorithm and successfully improved user experience. System improvements accounted for approximately $5 million in additional annual revenue and has become a standard heat control design on various fryer lines.Improved drawing and BOM structure to begin to incorporate assembly prints and controlled solid models using NX and TeamCenter.Conducted testing to establish life expectations of various components and systems.o Test process and fixture designo Data acquisition requirementso Statistical data analysis to establish life expectancy Show less

  • Senior Mechanical Design Engineer

    Jul 2017 - Oct 2020

  • Project Engineer

    Mar 2014 - Jul 2017
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  Midmark Corporation

  Oct 2020 - Jun 2022

  Mechanical Design Engineer III

  Developed next generation sterilizer pressure vessel.o Utilized Creo Simulation to analyze and refine design.o Worked closely with manufacturing engineering teammates to improve design for manufacturability. o Achieved 2.5 times current production cycle life to meet increased customer usage requirements.o Improved dimensional stability.Completed International Quality Federation DMADV Six Sigma training at Master Black Belt level. Currently using the following tools to aid in product development.o Design of experiments (DOE) to establish significant process variables and optimized settings.o Monte Carlo analysis to predict assembly yield given manufacturing capability for various features.o Utilize Minitab to aid in statistical model creation and data analysis.Mentor interns and engineers in the following topics.o Tolerancing and manufacturabilityo Test methodologyo System designo Data analysiso Model and drawing structureo Agency design considerationsWork with development team to create design requirements to meet customer needs documentation.Lead development of test protocols to verify design requirements. Show less

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  University of Dayton Research Institute

  Jul 2022 - now

  Team Lead - Space Power Systems