Manager Engineer

C. Brian Johns

**** *. ***** *******, **** Chester, OH 45069 – 615-***-**** – **************@*****.***

Career Summary

** ***** ** * **** Manufacturing environment as an engineer under both Nissan Production Way [NPW] and Schneider Production System [SPS]. Successfully launched five new models at Nissan from both Stamping Process and Field Quality roles. Design and Industrial Engineer on a Schneider Electric internal consulting team that performed a complete product analysis covering design, manufacture and supply base. The last three years have been spent in a Quality and Site Operations Manager roles in a Lean facility. Acting as the change agent, lead transition from one BU to another and a location move for two different product lines. Transitioning to a Lean Manufacturing Manager role in mid-August to gain experience in larger plant and a union environment.

Education

MBA - Vanderbilt University - Nashville, TN - Graduated Aug 2014 - Cum Laude

BSME - Tennessee Technological University - Cookeville, TN - Sum Cum Laude

Skills & Knowledge

USAF Veteran

Lean Manufacturing

PDCA

DMAIC

FMEA & FTA

Hoshin Kanri

Six Sigma Yellow Belt

GD&T & Dimensional Analysis

ISO 9000, 14000 & 18000

Excel, Word, PowerPoint

Toyota Production System

Theory of Constraints

5S

JIT

Project Budgeting

P&L

Team Building

Tool & Die Trials and Buyoff

Multi-level Presentation

22 month Expat in Japan

Productionizing

Industrialization

Continuous Improvement

Kaizen

Kanban

Change Agent

Data Analysis

Manpower/Capacity Planning

Safety & Accident Prevention

Root Cause Analysis

Experience

Schneider Electric - April 2011 to Current

Lean Manufacturing Manager - Oxford, OH - August 2016 to Current

New role, will be responsible for maintaining current SPS standards and implementing new standards as released.

Special projects at Plant Manager’s discretion.

Site Manger - West Chester, OH - May 2014 to August 2016

Staff of 80+ over five product lines in a 100,000 sq-ft facility, annual revenue 25-50M$ depending on demand.

Implemented 5S and SIMM Cycle meetings per SPS Standards.

Implemented SIMM Cycle boards (Visual Management) per SPS Standards.

Developed and implemented new Shadow Board standards and tool boards.

Transitioned from one temp employee service to another, reducing surcharge from 60% to 33%.

Established standard hour tables for manpower distribution and right-sizing floor staff for loading eliminating excess headcount.

Created scheduling system for the Integration product line.

Facility has not had a recordable OSHA incident.

Created new system for processing orders through manufacture for Integration product line including leader and technician check sheets.

Worked with HR to develop new wage table and positions reflecting the levels of pay.

Overseen Continuous Improvement efforts to increase productivity and ergonomics.

Created and instituted training program to achieve SPS goal of cross training reducing headcount for the elimination of specialized work groups.

Increased career development of and brought together a high performing team.

Quality Manager - West Chester, OH - October 2013 to November 2014 (7-month overlap of Site Manager role)

Worked in the Services Manufacturing facility overseeing the existing Quality System with ten QA direct reports.

Responsible for overseeing and ensuring that all Production Testing was performed and passed on standard and engineered to order products that left the facility meeting all quality standards.

Produced the Quality Department deliverables for ISO 9000/14000/18000 and for our internal Schneider Production System audits. Both audits were successful.

Achieved <0.56 Defect Per Unit levels by data analysis and communication to the Production Mangers of trends and repeat issues.

Won Supplier Improvement Achiever Award from Cummins Power Generation for work on the Bear project.

Implemented 5S and SIMM Cycle meetings per SPS Standards.

Design & Industrial Engineer - Smyrna, TN - April 2011 to October 2013

Product review to determine failings in: Design, Production or Supply Chain.

Performed design and production analysis including developing full FMEA suite.

Installed auto-paginating work instructions via touch screens at all production cells to SPS standards.

The system used Pro-Planner software to provide FO# specific work instructions.

Established time standards.

Presented findings and recommendation to senior management. The team won the bronze Connect Trophy in the company wide contest for efficiency.

Tolerance stack analysis on the 27kV breaker. Created a datum system on the parts to reduce tolerance stack from +/-0.75” to +/-0.35”. Presented findings to customer and was able to save a major contract.

Nissan North America - January 2003 through April 2011

Field Quality Engineer - Smyrna, TN - August 2007 to April 2011

Responsible for post sales quality and warranty investigations of new model launches.

New Model Task Force Leader for 2009 FX, 2010 Cube and 2011 Juke.

Studied warranty data and incoming warranty parts for trends.

Performed Root Cause Analysis on returned parts.

Worked with design engineering to develop and implement counter measures.

Entered findings into CARS system that reported to NHTSA

Worked with Nissan Recall group on fuel tank size discrepancy on Juke AWD.

Stamping Process Engineer

Was primary launch Stamping Engineer for 2004 Titan and 2007 Maxima.

Develop Process Sheets for material flow through blanking and pressing to NPW standards.

Productivity improvements via blank reduction and material trials. Each trial achieved model life savings from 2.5k$ (simple blank size reduction) to 250k$ (material and thickness change).

Part inspection both manual and with CMM

Established Stamping New Model Budget for 2007 Maxima project.

Determined press loading and rebalanced on 13 presses via time studies and NPW standards

Develop part and die improvement plan based on trial results and part layout reports

Work with other departments on fit and finish issues with panels.

Die trials and die buy-offs.

Did one-year assignment in Canton, MS for Titan Pickup and Q56 new model launches.

22 month Japan Expat Assignment for Die Design training and die development and buy off for 2007 Maxima.

Multiple Hospitals - Texas, Florida, Tennessee and Kentucky - Nov 1992 through Dec 2002

Medical Laboratory Technician

United States Airforce - Multiple locations in Texas - Nov 1988 – Nov 1992

Final Rank: Senior Airman. Honorably discharged. Received training and worked as Medical Laboratory Technician

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