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Customer Service Manufacturing

Location:
San Francisco, CA
Posted:
May 09, 2015

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Resume:

Patrick M. Johnson *** First Parish Road ( Scituate, MA 02066

***- ***-**** ( ********@***.***

Executive with proven success in operations, P&L, supply chain management,

lean manufacturing, and new product development.

Led $100+ million manufacturing operation to $18 million profit, 30% over

$14 million goal.

Spearheaded 25% capacity increase over 4 months to facilitate rapid growth.

OBJECTIVE:

Seeking a senior manufacturing executive position within a progressive

organization; offering professional growth, opportunities for advancements,

and dedicated to operational continuous improvement through lean

manufacturing.

PROFESSIONAL EXPERIENCE:

Rapid Machining Inc., Nashua, NH

$29 million contract manufacturer for defense, aerospace, industrial, and

medical

VP of Operations (6/13/14-Present)

. Full P&L responsibility for start-up machining and assembly operation.

. Increased revenue through operational efficiencies above breakeven

within first 4 months

. Transitioned plant to 24/7 four shift operation, and relocated to new

facility.

. Expanded machining capacity, increased machine utilization from 65% to

95%.

. Expanded staff across all disciplines, implemented shop floor control

and scheduling system

. Reduced machining cycle times by 50%, tripled capacity over 6-month

period.

SIG SAUER, INC., Exeter, NH

$500 million firearms manufacturer for sporting goods, law enforcement, and

government

Director of Operations (1/13/07-1/17/14)

. Managed all aspects of multi-site operation during high growth from

$60M to $500M over seven-year period.

. Full P&L responsibility for operations, $50 million in inventory, and

direct all aspects of 350 person manufacturing operation.

. Stabilized production to consistently achieve revenue and profit

targets.

. Improved supply chain flow, reduced component lead-time from 45 days

to 10 days, reducing WIP by $5.5 million.

. Applied lean techniques across all manufacturing departments,

implemented operational metrics and improvements.

. Restructured production control department, lead implementation of

standardized processes, and report development.

SMITH & WESSON COMPANY, Springfield, MA

$300 million firearms manufacturer for sporting goods, law enforcement, and

government

Manufacturing Business Unit Director (6/13/05-12/31/06)

. Key member of turnaround team, full P&L responsibility for business

unit.

. Quickly stabilized internal and external supply chain, increased

production by 300% during first year.

. Reduced scrap from $12k per week to $3k per week; reduced consumable

tooling spending by 50%.

. Restructured plant layout, implemented cellular manufacturing in

machining and assembly departments.

. Executing three year capital investment strategy supporting aggressive

business growth and product development.

. Replaced MRP with pull system for component manufacturing, increased

inventory turns from 5 to 8.

. Implemented continuous improvement activities across business unit,

targeting $1.5 million in savings.

FERRAZ SHAWMUT, INC., Newburyport, MA

Circuit Protection Group, $100 million manufacturing business unit

Director of Manufacturing (10/1/00 - 6/11/05)

. Developed strategic plan for 3 sites in US and Mexico. Managed 750

employees through 5 direct reports.

. Consistently met P&L targets during economic downturn through

effective operations/inventory management.

. Quickly resolved customer service crisis by reducing $1.6 million in

backorders during initial 3 months in position.

. Improved on-time performance from 85% to 97%, earning preferred vendor

status.

. Reduced standard cost 7.5% by implementing lean manufacturing and six-

sigma; saved $750k annually by trimming direct labor.

. Reduced total inventory 26%, from $18.3 million to $13.5 million, in

anticipation of economic downturn.

. Spearheaded divisional cost reduction initiative, reduced VME and FME

by $3.5 million over two year period.

. Applied lean material management strategy across supply chain,

outsourced non-core component manufacturing, established supplier pull

system, implemented raw material JIT replenishment and consignment

inventory program.

. Involved in 2 union contract negotiations teams, in both cases

achieved win-win results with no work stoppage.

. Leading conversion to new 3PL warehouse project to save $700k in 2004

while improving service level 300%.

. Reversed 6-month delay to complete critical project on time; retooled

Mexican plant, impacting 30% of all products.

Plant Manager (2/1/99 - 10/1/00)

. Directed all aspects of 240 person continuous manufacturing operation

in high-pressure, service intensive electrical market.

. Successfully manage P&L targets supporting operating budget, labor,

quality, capital budget, and inventory levels.

. Increased production capacity in US and Mexico operations; improved

customer service and exceeded profit targets.

. Facilitated $14 million sale of product line by addressing outstanding

issues and completed critical project on time.

. Completed numerous lean manufacturing projects improving, plant

logistics, cellular manufacturing, interplant pull system, raw

material supply chain, component inventory turns, and reduced

divisional cost by $1.3 million.

. Played key role in successful sale of business and subsequent merger

in support of corporate objectives.

Manufacturing Engineering Manager (8/5/96 - 2/1/99)

. Integrated advanced manufacturing and mechanical engineering into 18-

person department with $2 million budget.

. Overcame inherited 5-year backlog; completed 25 projects in just 2

years, regaining competitive position.

. Key player in joint North American / European development of $3.8

million fully automated assembly/component tooling system;

collaborated with engineers in Germany and Spain for successful on-

time completion.

. Developed numerous assembly cells, semi-automated and manually

assembly; transferred 12 assembly lines to Mexico facility.

. Managed multi-location capital budget, leveraged $2.5 million capital

investment to reduce cost and improve on-time delivery.

Manufacturing Engineering Group Leader (10/5/95 - 8/5/96)

. Restructured engineering department and streamlined new product

development process. Managed staff of 10.

. Created new product development Manufacturing Engineering Department;

recruited engineering professionals, developed technical skill

necessary for supporting product development objectives.

. Implemented pre-production area for assembly cell development, tooling

qualification, pilot runs, and initial production.

. Develop procedures for product costing, tooling development,

manufacturing strategy, and equipment specification.

. Heavily involved in product DFM, tool design, FEMA, equipment

selection, assembly cell design, and production integration.

ROCKWELL AUTOMATION / ALLEN-BRADLEY COMPANY, Chelmsford, MA

$95 million electronic manufacturer specializing in presence sensing

technology

Senior Manufacturing Engineer (10/1/91 - 10/1/95)

. Promoted to play key role in product development, coordinated up to 5

teams that designed technology to meet market needs while delivering

solid profit margin. #2 out of 150 R&D teams competing for Chairman's

Award.

. Instrumental in design of new product that yielded $9 million in

incremental sales and 65% gross margin.

. Delivered 2 new technologies within tight schedule, resulting in $5

million additional revenue.

. Mechanical team leader responsible for developing manufacturing

strategies; spearhead DFM issues, quality, cost, and schedule.

. Direct manufacturing engineers in developing tooling, equipment, cell

layout, process documentation, and pilot run activities.

. Responsible for selecting piece part fabrication approach, tooling

investment decisions, and vendor selection.

. Coordinate transfer of mature product lines from pilot facility to

domestic and offshore production facilities.

. Visit automotive customers, gained product application knowledge,

gather product concerns, define new product needs, and benchmarked

product against competitors.

Manufacturing Engineer (6/20/88 - 10/1/91)

. Justified and implemented manufacturing process cost reductions,

$275,000 for FY89-FY90

. Completely re-tooled acquired snap switch product lines; addressed

component tooling and assembly tooling issues.

. Project leader for developing fully automated test equipment,

developed technical requirements, managed capital budget, and

communicated project milestone progress to management.

. Analyzed and solved daily production floor issues, implemented

statistical process control and trained assembly associates.

. Supervised facility tool room, implemented scheduling system, and

managed budget.

ARK-LES SWITCH CORPORATION, Watertown, MA

$50+ million manufacturer of switches for appliances, automotive and other

industries

Manufacturing Engineer (4/1/87 - 6/20/88)

. Responsible for solving daily assembly issues: material, tooling, and

equipment.

. Determine disposition of nonconforming molded and stamped components,

resolved supplier issues, initiate corrective action.

. Justified and purchased capital equipment for productivity and quality

improvements.

. Established line balancing; set production labor rates based on time

studies, and wrote standard operating procedures.

. Supervised two in-process inspectors; performed process capability

studies, and implemented SPC (pre-control).

EDUCATION:

MBA, Finance, Northeastern University, May 1999

BS, Manufacturing Engineering, Rochester Institute of Technology, February

1986



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