Joseph Johnson

Work Experience

• Senior Lean Consultant

  World Competition Consultants
  10/1/2011 - Present  | Alcoa, TN

  Hired to convert a $1.9 billion company specializing in industrial/environmental filtration, engine/mobile filtration and consumer packaging to a lean enterprise. Taught platform lean classes to the Operations Manager, HR Manager, Materials Manager, Buyer, Planner/Scheduler, Group and Section Leads, Production Supervisors, Maintenance Manager, Mechanics, Warehouse Manager along with hourly stakeholders to gain buy-in of the President’s Lean Roadmap starting with the industrial/environmental filtration business unit plant in Pittston, Pennsylvania to prove that it works for the rest of the manufacturing facilities. ●Eliminated the need to keep $12 million of finished goods on hand by implementing a Just-In-Time/Kanban System. ● Slashed machine downtime from 8% to less than 1% by implementing a Total Preventive Maintenance System ●Increased through put time by 45% by value stream mapping the current operations, leading Kaizen Events and implementing standard work activities with Key Performance Drivers.

• Lean Project Manager

  LOWES
  1/1/2005 - 4/1/2008  | Mooresville, NC

  Hired to eliminate customer complaints due to 3rd party manufacturing supplier quality and delivery issues. (2800 employees in four manufacturing facilities generating build to order Kitchen and Bath Cabinet sales $240,000,000) ● Guided the four plant operations from an 8% customer reject quality ratio to less than 1% using Database Analysis, Cause & Effect Diagrams, Scatter Diagrams, Control Charts and Root /Cause Analysis for PDCA. ● Slashed late shipments to customers from 11% to 0% by scheduling to the constraint of the staining oven. ● Recaptured $12,000,000 in replacement and $60,000,000 in rework cost for 4 plants and customer confidence was restored by implementing lean manufacturing.

• Senior Lean Manager

  Mar Mac Construction Products Co Inc
  6/1/1998 - 1/1/2005  | McBee, SC

  Recruited to transform and improve this privately owned global matrix manufacturing company with four manufacturing facilities (2 US, 1 Xian China, 1 Juarez Mexico) plus 10 global sales offices with 1400 employees  Guided 2-day on-site and video streaming training sessions regarding lean methods for 10 sales offices and 4 U.S., Xian China and Juarez Mexico manufacturing facilities. Total 1400 employees. Followed the training with 3-day Kaizen exercises, allowing students to implement, within their respective departments, cost reduction efforts that cut operating costs 20%.  Value Stream mapped current and future state administrative, manufacturing and distribution operations with costs.  Participated and led the 25 member Accounting, Contracts, Customer Service, Human Resources, Information Technology, Marketing, Order Entry, Purchasing, Sales and Engineering, Inventory Control, Maintenance, Manufacturing, Production Planning/Scheduling, Quality, Receiving, Shipping, Warehouse Process Improvement teams at the flagship plant in McBee, SC conducting 57 continuous improvement Kaizen events over a 3-7 day period  Implemented order accuracy, production pick rate and order cycle times metrics for the distribution centers.  Eliminated aisle bottlenecks for pickers and forklift operators by scheduling orders that eliminated time wasted waiting until the picker or forklift operator cleared the aisle due to space constraints.  Rolled out and validated the Mar Mac Manufacturing Production System with lean performance scores and driver metrics (People-Output per labor hour, Direct labor per unit, Indirect labor per unit, Overhead cost per unit, Process-Setup time, On time delivery, Reject rate, Rework cost, First pass quality, Cycle time, Machine down time, Material scrap) using running LED displays and posted graph charts assuring attainment of business goals for 10 sales offices and 4 U.S., Xian China and Juarez Mexico manufacturing facilities. This endeavor provided permanent cost savings of $15,000,000 annually.  Championed transactional improvements by technology transfer to e-commerce by licensing the Sterling Commerce Internet interactive ordering system integrating it with the Great Plains/SAP solution running on an IBM AS/400, increasing family line earnings by 30% (Round 6%, Arched 8%, Elliptical 11% and Culvert 5%) allowing customers to place, change and monitor their orders 24/7 on the secured interactive website without speaking to a person.

Education

• Walden University

  MSc General Management
  2011-2012

  GPA 3.6/4.0

• DeVry University

  BSTM Operations Management
  2009-2011

  Academic Achievement: Dean’s List Accepted into the Delta Upsilon chapter of Alpha Sigma Lambda, national honor society

Awards & Certifications

Academic Achievement: Dean’s List
Accepted into the Delta Upsilon chapter of Alpha Sigma Lambda, national honor society
FUJITSU ● Six Sigma Lean Management ●Six Sigma Master Black Belt

Associations & Organizations

●Institute for Operational Excellence ●Institute for Lean Systems
●Lean Enterprise Institute ●Association for Manufacturing Engineers
●Lean Benchmarking Association ●Society for Manufacturing Engineers