Project Manager Engineer

Michael Ray Johnson, MSIE, (PMP pending */**)

**** ******** **** **** ( Cary, North Carolina 27519 919-***-**** (

***********@**.**.***

Senior Engineering Project Manager

EXPERT IN THE PLANNING AND MANAGEMENT OF PROJECTS THAT INCREASE EFFICIENCY,

PRODUCTIVITY, AND PROFITABILITY

Senior Industrial Engineering Professional with more than 20 years of

experience across diverse markets and industries. Strong track record of

cost reductions, process improvements, capital projects management, lean

transformation, and global contractor management. Particularly effective in

recognizing and delivering cost savings with limited capital investment.

Well versed in Six Sigma and Lean Manufacturing principles. Strong

background in Finance, SAP, supply chain and logistics. Semi-fluent in

Spanish.

Continuous Process Team facilitation

Improvement Cost Reduction Initiatives

Lean Sigma Instructor

Capital projects management New Production

Introduction

Professional Experience

Talecris Biotherapeutics - Clayton, NC

Jan 2009 -Dec 2009

CAPITAL PROJECTS ACCOUNTANT - (CONTRACTOR)

INTERFACED WITH ENGINEERING BUSINESS UNIT TO MANAGE CAPITAL SPENDING ON

PROJECTS UP TO $ 275 MILLION.

. DEVELOPED MONTHLY AND QUARTERLY CAPITAL SPENDING FORECASTS AND ANNUAL

CAPITAL BUDGET FOR SELECTED PROJECTS

. COORDINATED WITH ACCOUNTING DEPARTMENT TO ENSURE PROPER MANAGEMENT AND

REPORTING OF SELECTED CAPITAL PROJECTS, PLANS, AND BUDGETS

. DEVELOPED POST COMPLETION REVIEW PROGRAM FOR ALL COMPLETED CAPITAL

PROJECTS TO IDENTIFY IMPROVED WAYS OF WORKING FOR FUTURE PROJECTS

. ASSISTED PROJECT MANAGERS WITH WRITING BUSINESS CASES TO JUSTIFY CAPITAL

EXPENDITURES

GLAXOSMITHKLINE - ZEBULON, NC 2000 TO JULY 2008

LEAN SIGMA EXPERT (2005 TO JULY 2008)

Supported the 250 employee solid dose manufacturing department for this

$3.6 billion pharmaceutical manufacturer, leading cross-functional teams in

the implementation of several process improvement initiatives to enhance

production efficiency, deliver cost savings, and mitigate risks.

. Led initiative for tablet compression equipment that reduced changeover

time 67%, from 52 to 17 hours, increased capacity 20%, and delivered $1

million in cost avoidance without any capital investment.

. Reduced changeover time on tablet coater 48%, from 24 hours to 13 hours

by improving current ways of working procedures.

. Facilitated many Lean Sigma events to identify and mitigate risks

associated with pharmaceutical manufacturing and packaging processes -

performed Kaizens, after action reviews, failure mode and effects analysis

(FMEA), root cause analysis, 3-day baselines, Value Stream Mapping, 5S,

and SMED

. Developed material usage variance and cost of poor quality reports from

SAP to determine quality improvement projects and to develop scrap

percentages for annual operating budgets. Analyzed and recommended cycle

times, standard scrap percentages, headcount, and yield information for

biannual standards build used to develop annual operating budget

. Created and maintained approximately 2500 site production routers and

master recipes in SAP to accurately measure cost of production inputs

. Taught approximately 100 Six Sigma Green Belt candidates and 350 White

Belt candidates on site

. Managed GSK network information as Zebulon site Knowledge Manager

Senior Cost Analyst (2003 to 2005)

One of three Financial Analysts providing financial analysis support for

the Zebulon site. Served as lead financial analyst on new product teams and

developed standard cost of new products and manufacturing processes for R&D

products. Compiled financial data for site and above site budget forecasts

. Developed site operating budget for labor and overhead recoveries in

support of $160 million dollar budget.

. Contributed to project to cutover all financial records from AMAPS to SAP

and investigated improper cost issues in SAP.

. Evaluated financial impact of various mix and volume change scenarios

. Quantified benefits of proposed changes in products or processes

Senior Industrial Engineer (2000 to 2003)

Provided Industrial Engineering support for manufacturing and packaging

departments of pharmaceutical manufacturer (Approximately 500 people out of

1100 on site.)

. Saved approximately $2 million in direct labor cost and cost avoidance by

Identifying and implementing continuous improvement projects

. Evaluated site impact of potential new products on equipment utilization,

cash flows, and labor utilization

. Improved dryer capacity in finishing facility by 30 minutes per day by

changing time for filter change. This resulted in a $400,000 cost savings

with a zero dollar investment.

Sara Lee Underwear (Hanes Underwear) - Winston-Salem, NC 1992 to 2000

Contract Manager (1996 to 2000)

Located, qualified, and managed production and quality issues for 40 global

contractors in the United States and 15 other countries generating $200

million in annual revenue. Negotiated prices and terms for contract

production. Resolved supply chain, logistics, and customs issues.

. Traveled as needed to provide on site support for quality and process

improvements

. Set up contractors in Sara Lee systems for quality, payroll, and

production functions

. Located financing for Far East joint ventures

. Represented Sara Lee as single point of contact for contract

manufacturers

Senior Industrial Engineer (1992 to 1996)

Developed $30 to $40 million annual and quarterly spending plans for 8

apparel manufacturing facilities located in the United States, Central

America, and the Caribbean. Determined new product costing; certified

vendors to meet Sara Lee preferred vendor criteria.

. Prepared cost/benefit analyses to determine whether to buy equipment or

hire contract manufacturers

. Managed capital projects up to $2,000,000

. Represented engineering for new product introduction teams

. Assisted equipment vendors with design of specialized packaging equipment

. Designed week long training class for 6 international engineers

Northern Telecom - RTP, NC 1989 to 1992

Manufacturing Engineer

Provided engineering floor support for circuit board assembly operations.

Wrote assembly instructions for components to be inserted onto circuit

boards.

. Balanced tasks at work centers to improve process flow

. Investigated quality issues and wrote alerts as needed to pull product

out of the production area

. Updated manufacturing information when products were updated due to new

technology

. Developed 8 hour Methods and Standards class to educate line and staff

management on process improvements

Education & Certifications

Masters of Science in Industrial Engineering with Management Emphasis North

Carolina A&T State University - Greensboro, NC

Bachelors of Science in Industrial Engineering North Carolina A&T State

University - Greensboro, NC

Certifications

Lean Sigma Expert - GlaxoSmithKline 2003

PMP (pending April 2010) - Project Management Institute

Keywords

PMP, Lean Manufacturing, Six Sigma, Cost Reductions, SAP, FMEA, Cost

avoidance, Process Improvements, Root Cause analysis, Project management,

Yield management, supplier management, safety, quality, budget, finance,

operations, baseline, knowledge management, change management

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