TREVOR R. JOHNSON 214-***-****

Rockwall, TX ***32 acoyei@r.postjobfree.com

MANUFACTURING / OPERATIONS EXECUTIVE: COO, VP

More than 20 years executive, leadership and management experience in manufacturing

operations. Strong portfolio of achievements including 6-figure and million-dollar cost

reductions, 180-degree turnarounds for underperforming operations, fast-track growth, and

significant quality, productivity, and efficiency improvements.

Extensive experience and field knowledge in plant start-ups, closings, turnarounds, acquisitions

and consolidations. Innovative leader in achieving production efficiency and accuracy. Able to

manage complex, multimillion-dollar operations and projects to success.

KNOWLEDGE AND SKILL AREAS:

Process & Cost Control Continuous Process Improvement Executive-Level Decision Making

Manufacturing Operations Management Operations Turnarounds Enterprise Solutions High-

Performance Team Facilitation Budget Management Strategic Planning & Execution Project

Planning & Execution Process Optimization Lean Manufacturing Cost Reduction & Avoidance

Inventory Management Control Facility Planning Capital Improvements

Penn State Executive Programs: Managing Effective Supply Chains; Developing Managerial

Effectiveness Program.

BS - Plastic Engineering Technology / AS - Mechanical Engineering Technology, Pennsylvania

State University.

LINKS

Linked In Profile: https://www.linkedin.com/in/trevorrjohnson1

Executive Profile: http://executivecareerspotlight.com/portfolio/trevor_johnson

HIGHLIGHTED ACCOMPLISHMENTS

Negotiated 15% cost reduction on critical supply item, reduced lead time by 60 days, and

achieved an annualized $1M savings from top 3 vendors.

Implemented process controls that drove reduction in overtime requirements by 500+ hours

per month and reduced in-process inventory from 90 days to less than 45 days.

Collaborated with manufacturer to develop a new nylon resin for automotive transmissions

and negotiated acceptance at Ford and GM, producing $1.1M material savings annually.

Right-sized the manufacturing footprint from three plants to one in 2008 when the division

was transitioned away from retail customers (40% of revenue) and there was a dramatic

decrease in housing starts to improve EBITDA by 200 basis points. Leadership produced

18%+ division sales growth over five year period, to $78M annually.

Developed key business partnerships and added production capacity to meet 40% increase in

product demand

Implemented lean manufacturing, value stream mapping, 5S methodology, and total

preventative maintenance at two plants, reducing scrap in one product line by 8% and in a

second line by 13%.

Trevor Johnson Resume – Page Two

EXECUTIVE EXPERIENCE

Zurn PEX Division, 1999 to 2014. $75M division of Zurn Industries, LLC, a recognized leader

in commercial, municipal, and industrial markets with revenues exceeding $500M. . Subsidiary

of $2B+ publicly traded Rexnord Corporation. Division manufactures and distributes residential

and commercial plumbing and radiant heating products.

General Manager – 2003 to 2014. Full range of senior management responsibilities

including strategic plans, budget, sales, $30M P&L, and facilities and equipment with $1M

CAPX budget. Coordinated closely with extended business partner in driving culture of safety,

delivery and cost out.

Drove 10% annual sales growth through three area managers and 37 manufacturer’s

representative agencies.

Created a kanban system for Lowes and Home Depot, improving fill rates to 98%.

Managed 20+ suppliers in 6 countries with $30M in purchases.

Improved product availability to 95% on 1,600 SKUs, maintaining 95% on-time delivery.

Right-sized manufacturing footprint from three plants to one when division transitioned

away from retail customers producing 40% of revenue in the face of dramatic decrease in

housing starts, improving EBITDA by 200 basis points.

Developed sales plan that grew sales from $66M to $122M million from 2004 to 2008

while maintaining customer satisfaction and on time delivery.

Operations Manager – 2001 to 2003. Managed 250 people at two plants running 10

extrusion lines and 4 packaging departments 7 days a week. Managed the R&D and hydronic

design departments in Erie, PA plant.

Implemented $1M in CAPEX projects per year.

Increased extrusion and curing capacity by 20% per year to meet annual sales growth.

Drove quality initiatives to reduce DPPM by 30% annually.

Manager of Molding, Assembly and Packaging – 1999 to 2001. Managed molding

department of 36 employees with 20 injection molding machines.

Led startups on 26 new molds - $1M in capital for the chemical drainage product line.

Reduced overtime by 500 hours per month and decreased workforce.

Decreased molding work in process from 90 days to 45 days.

Eliminated product rework and overtime.

Director of Technology, SPX Filtran - 1998 to 1999. Managed design, development and testing

departments for automotive transmission filters for Ford, GM, Chrysler, and Honda in the USA

and Europe. Led 11-member team with P&L exceeding $2M.

Implemented finite element analysis software and rapid prototyping reducing

development costs and tooling re-work.

Reduced annual plastic resin costs by $1.1M, a 20% savings.

Developed QS-9000 documents for all design development and testing procedures.

Earlier Career: Account Manager / Application Engineer, C-MOLD - 1993 to 1998. Managed

the East Coast sales region for simulation software for injection and gas assist molding.

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