Sign in

Manager Injection Molding

Woodstock, Illinois, 60098, United States
October 02, 2016

Contact this candidate


Raymond J. Johnson ** Clayton Avenue

Lake Villa, IL

CELL 847-***-****


A manufacturing management position capitalizing on success as a cost-cutter and profit driver.


Manufacturing professional with specialized expertise in Blow molding and painting operations.

Strategic and tactical planner. Experienced in developing, justifying, and managing $5 million budgets.

Innovative cost-cutter. Introduces Lean, 5S concepts, quick change processes, MRP and robotic technologies, as well as starting up new departments and multiple shifts to optimize capital and labor resources.

Open management style builds strong partnerships with staff, executives, vendors, and customers. Creates a no fear culture that produces fast solutions to problems before costs escalate.

An AS degree plus extensive professional training. Computer skills include AS 400, BPCS MRP system, and MS Excel.


12/28/09 – Present- Sunstar Americas Inc.

Production Manager

Responsible for Molding / Secondary Operations

Key Metrics Include

$150,000 in Labor savings over 3 Departments

Develop and oversee 5S program

Improve scrap reporting from 68 to 95%

10/01/2007 – 11/01/2009 Consolidated Container Co.

Operations Manager / Maintenance Manager

Responsible for all plant / Maintenance operations.

Key Metrics Include

Safety – OIR = .9 for 2008 VS company goal of 2.5 /2009 OIR of 1.0 VS company goal of 2.1

Resin Yield- 98.3% YTD VS company goal of 97.8%

Labor Cost Per. Pound- $.163 Total Labor VS Company goal of $.176

At 22MM pounds.

Cut Labor costs by $120,000 per year

Plant Spending / Quality Costs

Responsible for all plant operations Production, Materials, Quality, Maintenance

Monthly P & L // Capital Projects

July 2006 – 09/30/2007 Consolidated Container Co.

Production Manager

Oversee all production in a 24/7 Blow Mold Operation

10 Wheel lines / 100,000 LBS + Daily

Food Grade and Non-Food Grade Bottles

Labor Cost Per. Pound

Oversee plant G.P.M. Audits

1985- June 2006 Solar Corporation Libertyville, IL

PLANT MANAGER 1995- 06/23/06 Plans and manages daily operations of two-shift injection molding and finishing plant producing painted plastic components primarily for the automotive and home entertainment market. Clients include General Motors, Johnson Controls, Sony, Bose, and Mitsubishi.

Teams with executive level on strategic planning Develops annual capital budgets as well as departmental budgets of $50,000 to $2.5 million for indirect/direct labor, overtime, and supplies.

Hires, coaches, and directs 12 supervisors plus paint technicians tasked with programming robots. Oversees hiring and direction of 300 workers in six departments: Vacuum-forming, die-cut laminating, roll coat, cloth, large frame assembly and decorative.

Maintains high visibility and applies active listening skills in dealing with supervisors and production staff. Meets with supervisors twice a day/shift change; includes production planner in scheduling of staff.

Forms taskforces to identify and implement cost-saving initiatives,

Requires JIT deliveries from suppliers and to clients.

Works directly with client’s engineers and purchasing on-site for launch of new programs and first runs. Problem-solves production issues on weekly conference calls.

Saves approximately $100,000 a year on process improvements by tracking and analyzing productivity, waste, and quality.

Conducts time and motion studies to identify bottlenecks and balance production. Introduced "quick change" to line operation.

Team leader of Scrap Reduction and Paint Improvement taskforces.

Proposed and gained approval to introduce Lean Manufacturing and 5-S program. Brought in AMA Lean Instructor for initial assessment. Reduced resistance to change by building implementation team over time and selling benefits to staff.

Finds balance with long-term vendors through honest approach; brings in competitors as needed to achieve cost goals.

Investigated establishment of painting plant in Mexico with local strategic partner/molding plant.


Developed department budget, Hired, trained, evaluated and mentored six line supervisors; oversaw staff of 50 applying water-based paint to plastics.

Department was recognized in the industry as one of the best painting operations in the Midwest.

Expanded department from two to seven robotic lines.

VACUUM-FORMING Supervisor 1985-1990

Managed single-shift operation with 30 direct reports, personally handled training, safety, quality, productivity, housekeeping, and payroll functions.

Produced 250-1,600 pieces a day on 6-up tool, such as TV backs from Styrene.




Escanaba, Michigan


TRAINING: QS9000, Statistical Process Control, Supervision, Value Management (GM), Lean Manufacturing (AMA), 5S (AMA), Problem-Solving (Sony), Total Quality Management (College of Lake County), Injection Molding (Elgin Community College) Toyota Production System (AMA)

Value Stream Mapping (TMA) Kaizen Blitz (TMA)


Would relocate for right opportunity.


Contact this candidate