Project Manager Plant

TODD A. JOHNSON

Normal, IL

Cell 309-***-**** Home 309-***-**** Email: ************@*****.***

Sr. Manufacturing Executive - Innovative and dynamic leader with extensive union and non-union manufacturing

experience. Accomplished record of strategic and operations improvement for small and large companies.

Champion of Lean / Continuous Improvement. Nationally-certified Lean trainer/implementer & Lean presenter at

two National and numerous Illinois manufacturing conferences. Highly-developed influencing skills at all levels –

from factory floor to C-level executives to multi-state economic development officials.

PROFESSIONAL EXPERIENCE

CAMtek, Inc. $13mm+ annual sales – contract assembly of printed electronic circuit boards.

Director Continuous Improvement Bloomington, IL 2009 - 2010

Led enterprise-wide business improvement initiatives – achieved $8.1+ million impact to the enterprise.

• Initiated and attained $2.7+ million in business expansion incentive offer packages (1.7+ Indiana, 1.0+ Illinois).

• Conducted in-state & out of state facility acquisition due diligence assessments, sourced 35 contractors and documented $2.8

to $4.3 million in required renovations, resulted in $2.0+ million price reduction. Wrote the comprehensive assessment

report and created unique Lean Visual documentation of facility layout and issues.

• Identified & engaged outside IT resource to generate new ERP report used by purchasing to achieve $200 thousand in

domestic and off-shore supplier cost reductions in 1st 3 months of report usage.

• Researched & identified up to $176,400 in tax deductions for energy-efficient building renovations.

• Conceived & implemented new pro-active ALERT communications tool, preventing quality / production issues.

• Led first ever company-wide Lean training followed by ongoing 5S implementation.

• Reduced Receiving backlog from 4 days down to 0 days, utilizing multiple Lean methods.

• Created and implemented numerous visual management tools throughout manufacturing.

• Analyzed business processes & identified over $225k in Lean project improvement opportunities.

• Technologies include Surface Mount, Thru-Hole, Leaded & Lead-free Wave & Selective Solder, Box Builds.

KERRY

Plant Manager, IL $60 million annual sales 2008 to 2009

Directed 2 plant sites, including production, maintenance, quality, materials, warehouse, sanitation, & safety.

• Led existing & new operations during $10 million expansion project, more than doubling the square footage.

• Commissioned 2 new production lines, generating a 50% increase in production volumes.

• Managed 6 additional capital investment projects from initiation to completion.

• Doubled the size of the workforce, hiring & training in 6 months, to be able to produce new products on new lines.

• Achieved highest possible ratings on 4 external audits, 3 from world class customers.

• Achieved the best safety performance of all plants in division.

• Developed and implemented visual work instructions for production workforce.

Illinois Manufacturing Extension Center (IMEC) / Illinois State University

Manufacturing & Lean Consultant / Project Manager, Normal, IL 1999 to 2008

Worked with top executives of firms of all sizes to improve business performance. Analyzed needs, recommended solutions,

sold, implemented, and managed the engagements. Conducted Lean / Continuous Improvement training and implementations

throughout the United States, led multiple-day factory-floor kaizen improvement projects. Lean / Continuous Improvement

training for John Deere, CAT suppliers, General Mills, Pactiv - additional factory floor implementations include:

Hydro-Gear (hydrostatic transmissions) Interlake (warehouse racking systems)

Homeshield (aluminum fenestrations) Methode (electronics assembly)

Alamo (agricultural equipment) FMC (herbicides)

Agri-Fab (lawn & garden equipment) MidWest Biosystems (ag composting equipment)

• Conducted over 100 Lean training/kaizen improvement activities, 1-5 days long, for over 30 companies.

• Provided direct technical expertise in over 83 plants, 54 in Illinois, 29 Midwest / Nationwide.

• Delivered Lean / technical expertise on over 170 improvement projects, for those 54 Illinois plants.

• NIST-MEP certified trainer & implementer for Lean Overview, VSM, 5S, SMED, Cellular, Pull/Kanban, and TPM.

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TODD A. JOHNSON Page 2

Operations Improvement Consultant 1998

Analyzed operations, increased production performance by 36%, generated saving of $8,700/ day, $2,000,000 annually.

NESTLE USA, $8 billion, Kathryn-Beich division.

Vice President Operations Bloomington, IL 1995-1997

450 employees, $130 million in annual sales

Directed all plant operations, including manufacturing, maintenance, engineering, industrial engineering, materials, quality, and

purchasing. Annual production of 52 million lbs. Developed and managed the overhead budget, capital investment plan, and the

strategic operations plan, manufacturing for 8 Nestle operating groups. Negotiated labor contracts with all four unions.

• Initiated and completed a strategic operational restructuring of 8 packaging lines, enabling installation of 2 new high speed,

high volume production lines without plant expansion.

• Developed and conducted a highly successful operations marketing effort, bringing 3 new Nestle products into facility,

constituting over 23 million lbs. of new production and $12 million in new capital investment.

• Increased plant wide efficiency 16%.

• Increased line output on a critical production line by over 83%, without capital investment.

• Identified method that saved $1 million of product in distributors' warehouse.

• Installed a $3.5 million production line including 3 high speed baggers.

GOLDEN CAT CORPORATION, a $200 million consumer products company.

Plant Manager Bloomfield, MO 1993-1994

approx $100 million in annual sales this facility

Directed all aspects of plant operations, budgeting, and planning. Developed and managed a $27.5 million operating budget,

capital plans, and maintenance plans for a facility packaging over 330,000 tons annually.

• Re-engineered packaging line jobs into High Performance Work Teams and achieved 25% increase in output.

• Co-developed and installed a Gain-Sharing program; achieved over $273,000 in gains shared in first year.

• Improved product quality rating to 96% from 58% on compliance audits.

• Improved shipping performance to 99% on-time delivery.

• Managed ongoing operations through a series of line automation capital projects for 6 out of 7 packaging lines, as part of a

$3.5 million capital plan.

• Championed SPC & process capability studies, aligning manufacturing capabilities & marketing goals.

THE DIAL CORP, a $1 billion consumer products company, part of a $3.5 billion conglomerate. (12 yrs) Prior Experience

Plant Manager

Directed plant operations, including production, maintenance, quality control, labor relations, safety, and GMP's.

Developed budgets, operating plans, capital investment projects, and cost reduction projects.

• Directed a highly successful plant turnaround, from unprofitable to highest % ROE of all plants in division.

• Reduced costs by over $455,000 in overhead, labor, raw materials, and packaging.

• Achieved best safety record in the plant's 26 yr. history, attaining over 5 yrs. without a lost time accident.

• Directed the successful start-up of a liquid form/fill/seal packaging line, achieving $300,000 in savings.

• Strategically redeployed workforce into job-sharing and flexible work assignments, in a Teamsters union plant.

OTHER

MBA Operations Management / Human Resources / Marketing - Benedictine University, Lisle, IL.

BA University of Northern Iowa, Cedar Falls, IA.

LEAN Nationally certified trainer/implementer for Lean Overview, VSM, 5S, SMED, Cellular, Pull/Kanban, & TPM

6 Sigma Green Belt training & Six Sigma tool usage in multiple plants over many years.

SALES Sandler System and Zenger-Miller sales training

Soldering IPC J-Std-001 Certified IPC Specialist

Board Member, Manufacturing Sequence Advisory Board, Department of Technology, Illinois State University

Lean Presenter, Society of Manufacturing Engineers 2004 Manufacturing Technology Summit, Detroit, MI

Lean Presenter, National Association of Industrial Technologists 2003 Annual Conference, Nashville, TN

Lean Presenter, Illinois’ Manufacturing Matters Annual Conference, multiple years.

Graduate work, Strategic Management and Organizational Development

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