Steven E. Johnson

https://www.linkedin.com/in/steven-johnson-0977729

*** *********** ***** act47n@r.postjobfree.com

Fultondale, AL 35068 H and M: 256-***-****

Accomplished and results driven senior operations and site leader with responsibilities comparable to General Manager. Over fifteen years experience utilizing lean manufacturing to drive out costs and maximize operations productivity, growth, profitability, employee retention and accountability.

Effective leadership experience in multiple industries with dedicated commitment to safety, quality, customer service and cost control. Professional approach that promotes and inspires individual contributions, teamwork and accountability delivering excellent operations performance.

Superior technical knowledge in plant management, labor relations, lean manufacturing and industrial engineering techniques. Leadership experience with both union and non-union labor in multi-shift and multi plant medium to large companies ranging from 60 employees up to 600 employees and generating operating revenue ranging from 30m up to 150m per year.

Developed and implemented S.O.P. that ensured compliance, eliminated waste, improved productivity and quality leading to increased customer satisfaction & retention. Business revenue growth of five million dollars over four years in a recessed economy.

Led employee relations initiatives which engaged employees leading to a changed culture with improved employee retention, rigorous employee involvement, employee accountability and ultimately leading to union decertification.

Championed C.I. projects which were successful in generating approximately one million dollars per year in reduced labor, improved productivity and material savings resulting in greater operating profit.

P & L, Budgeting & Capital Budgeting

Supply Chain Management

Sales and Customer Service

Employee / Labor Relations Skills

Environmental, Health & Safety

Certified Lean Manager

Positive Results oriented attitude

Five S Implementation

Six Sigma Certification

Strategic Planning

Project Management

Effective Team Building

Demand Flow Technology

Industrial Engineering MOST

Development and implementation of standard work / S.O.P

Intelligent, Organized, Engaged and Practical Problem Solving

Excellent Communication Skills

High Integrity and Honesty

Chemical Mixing of Resins

Thermo-set casting process

Analytical Testing

Carbon and Stainless Steel forming, fabrication and finishing

Roll Forming, Deep Draw Dies, Stamping

Powder Coat Paint, Decorative Anodize, Silk Screening and Chrome Plating.

CNC Saws, Routers, Milling Centers, Robotics Welding, MIG & TIG Welding

Cabinets and countertop fabrication

Metal or Wood RTA or fully assembled office furniture

Epoxy Resin Lab Tops and accessories

Automotive & Appliance Decorative Trim

High speed assembly and packaging

Wood Fabrication, Laminating, Milling and Finishing

Thermo and Vacuum Form Plastics

Packaging, Shipping and Receiving

Audiovisual Carts, Cabinets

Point of Purchase Displays

Water Waste Treatment

The Kent Corporation

Director of Manufacturing Operations Birmingham, AL 2014 to 2016

Kent Corporation manufactures a large variety of Point of Purchase merchandise displays for the grocery industry. Kent is a privately held corporation employing approximately one hundred non-union hourly employees. Processes include metal blanking from master coils, stampings, roll forming, resistance, mig and stick welding, powder coating, assembly and packaging. As Director of Manufacturing Operations I manage a direct staff of eight and am responsible for planning and directing all plant activities including but not limited to production scheduling, plant operation and maintenance, appropriate staffing, supply chain management, on time shipment/delivery, receiving, continuous improvement, quality assurance, customer relations as well as compliance with corporate policies, legal and environmental matters.

Implementation of Lean Manufacturing

FIFO Inventory stocking program

Implementation of Labor Tracking to improve Plant Capacity Planning

Implementation of rotating shift schedule to manage peak demand with minimum OT

The HON Company

Supply Chain & Continuous Improvement Manager Florence, AL 2013 - 2014

HON, a division of HNI Corporationthe second largest Office Furniture manufacturer in the U.S., Florence manufactures RTA and Fully Assembled products serving the business and education markets. My responsibilities include Procurement, Receiving, Inventory Management, Store Issues to Production, Production Scheduling and Shipping. Additionally my RCI responsibilities include driving continuous improvement of operations. Direct reports include Shipping/Receiving/Stores Supervisor, Production Scheduler, two Procurement Analyst, two Industrial Engineers and one Continuous Improvement Tech.

Lead team to improve material utilization over $300k YTD

Participated four Shingijutsu Continuous Improvement Events

Conducted 40+ kaizen events delivering over 600k annualized cost savings

Implemented Supply Chain MDI process

Team member driving Supplier Collaboration

Implemented General Order Tool to improve material control

Implementing “Parts Rack” barcode scanning inventory control

Team member planning for Oracle implementation for 2015

Thermo Fisher Scientific

Plant Manager and Site Leader Mountain Home, AR 2008-2012

Thermo Fisher Scientific is the world leader in serving science. Serving education, medical, biotech and research markets the Mountain Home site produces chemical resistant work surfaces for the laboratory environment. Chemical mixing, reactive thermo-set molding and fabrication of this stone like material is performed 24/7. Process includes formulation and casting of chemical thermo-set epoxy resin and fabrication of same utilizing wet and dry CNC cutting and milling equipment. As Plant Manager/Site Leader I managed a direct staff of nine and was responsible for planning and directing all plant activities including but not limited to production scheduling, plant operation and maintenance, appropriate staffing, supply chain management, on time shipment/delivery, receiving, continuous improvement, quality assurance, customer relations as well as compliance with corporate policies, legal and environmental matters.

Achieved record operating profits and sales revenue growth of 21% 2008 to 2012

Reduced scrap and offal by improving first pass yield and material optimization. (10.5% COGS to 8.3%)

Union to Non-Union - Improved employee relations leading to union decertification in 2012

Developed an enhanced continuous improvement program utilizing TPS, PPI, Kaizen and 5S

Eliminated top two Quality issues through establishing SOP and audit process to ensure compliance

Achieved and sustained ON TIME DELIVERY from Q1 of 2009 to Q3 2012

MASCO Builder Cabinet Group

Plant Manager and Site Leader Adrian, MI and Las Vegas, NV 2006 – 2008

The number one builder preferred, manufacturer of stock kitchen and bath cabinets. Six high-speed assembly lines and thermo foil operations on two shifts. Culture highly focused on continuous improvement, one-piece flow and adherence to 60 second tact time. Continuous improvement focus utilizing kaizen and DMAIC problem solving throughout the organization. Operation with up to 600 non-union employees operating on 2 shifts.

Implemented safety improvements which reduced recordable incident rate to under 3.0

Total organization involvement 5S program developed and sustained.

Six Sigma project that eliminated an environmental issue of high level of suspended solids in waste water stream. Suspended solids were reduced by over forty percent to well within permit limit.

Jami Corporation

Plant Manager ABCO Office Furniture Florence, AL 2000-2006

Jami manufactures metal, wood, wire and plastic office furniture products under several brand names including ABCO, Fixtures, Harter and Zoom. Processes include metal stamping, tube bending, deep draw metal forming, robotic welding, CNC wire bending, steel tube manufacturing, wood laminating, powder coat paint, CNC routers, CNC machine centers, edge profiling and packaging on a two shift 300 non-union employee operation.

Significantly reduced Jami operations costby consolidating the Fixtures Seating operations into the Florence ABCO plant.

Transferred equipment and produced OEM folding tables generating an additional six million annual revenue stream

Implementation of lean manufacturing at ABCO including value stream mapping, kaizen and 5S

Revenue per direct labor hour improved by 41% over three years through continuous improvement/ Lean Manufacturing events

Increased speed of order throughput from 5 to 3 days by developing a robust scheduling and production process. Eliminated $250k finished goods inventory required for quick ship orders

American Trim LLC

Business Unit Manager Cullman Products Division, Cullman, AL 1998- 1999

American Trim is a major manufacturer of decorative metal trims for the automotive and appliance industries.

EBSCO Industries Inc

Plant Manager Vulcan Industries Moody, AL 1997 - 1998

Manufacturer of audiovisual carts, metal storage cabinets and a leader in “Point of Purchase” merchandise display industry.

Haworth International

Plant Manager United Chair Company Leeds, AL 1981 - 1996

The largest manufacturer, ISO 9001 Certified, of high quality steel frame office seating in the Eastern United States.

Other positions with United Chair’s Leeds Division included: Engineering and Distribution Project Mgr. (1 year), General Foreman, (3 years) Distribution and Final Assembly Departments. Supervisor, (5.5 years) Assembly Dept. Quality Assurance, (1.2 years), Customer Service (1.5 years)

Bachelor of Science in Business Administration 1989

Birmingham Southern College (Business Management and Human Resources Focus)

Associate in Applied Science 1982

Jefferson State Jr. College (Management and Supervision Technology Focus)

Six Sigma Certification, Green Belt Training Juran Institute, Southbury, CT 2007

Certified Lean Manager Univ. of Alabama –Huntsville 2004

Demand Flow Technology & Advanced Mixed-Model JCIT Englewood, CO 1999

MOSTCertification (Maynard Operation Sequence Technique) 1981

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