Johnston, Michael Email & Phone Number

Ooltewah, Tn, Us

Chattanooga, Tennessee

· Led a team of Process Engineers to launch new production lines and products in a brown field environment. · Responsible for designing/optimizing the production process and equipment. Over 800 robots including welding, material handling, laser welding, vision measurement, and sealer application processes. · Continuous improvement of all manufacturing processes including the design of the workstations and the flow of material. Over 400 process improvements in one year. Improved OA from 50% to 85% target.· Identify and avoid waste within the operation to establish lean manufacturing. Managed several projects that reduced the cost per unit. (Reduced scrap cost by over $6 per unit)· Set up quality proof plan to catch quality defects and to keep them from shipping. Improved quality audit scores to achieve consistent quality control target of 1.6.· Led several cross-functional workshops to improve the process. (Achieved 6 process reductions that led to a $500,000 savings per year)

United States

· Led teams of Supervisors, Production, and Quality Team Members in an automotive manufacturing environment. · Direct reports: 6 Indirect reports: 100+· Launched the all new Volkswagen Atlas in a brown field environment.· Managed the production process to ensure processes meet safety standards, quality standards, ISO standards, and OSHA regulations. (ISO 50001, ISO 14001 and ISO 9001).· Monitored OEE, cost, and productivity. · Completed annual performance reviews and created development plans for direct reports.

· Managed several quality service contracts with an annual budget of 8 million dollars. Responsible for all contract negotiations. · Industrial cleaning contract direct reports: 1 Site Manager, 1 Operation Manager, and 30+ Team Members. Achieved a 3 year cost reduction of $2,000,000+ while driving down the defects per unit from 12 DPU to 8 DPU. · As the local technology expert, I worked with production, quality, engineering, maintenance, and safety to optimize production quality/processes. · Started up a microscopy dirt analysis program to improve quality. Improved First run rate 70% to 80%

I was the first Maintenance Supervisor hired for the plant startup. Responsible for complete set up of Paint Maintenance Department systems and TPM structure. Benchmarked Germany plants to develop man power plan. Conducted over 160 interviews during the hiring of 68 maintenance personnel including 5 specialists. Developed maintenance organization. Conducted daily meetings with equipment venders to identify and correct open points and design issues. Developed our equipment groupings and overall equipment organization. Scheduled over 250 production and maintenance training sessions as project leader over training. Led a team of specialists in designing and developing preventative maintenance schedules. Performed overall time study for running vs. non running PMs to aide in man power decision. Led a team of specialists in designing and programming a work order system for tracking work done on the equipment. Developed KPIs for PM completion, work orders, downtime, Operational Availability, Reliability MTTR MTBF, training, and cost. Created breakdown analysis tracking system. Project leader for developing Thermal imaging and vibration analysis predictive maintenance program. Led project to redesign and implement new pump bases using laser alignment equipment. This project increased pump alignment precision and greatly reduced pump vibration. Lead a team of specialist in setting up our fixture repair system. Developed master lists, worked with finance to get funds, and ordered all tools for the paint shop. Led team of specialist to specify and work with finance to get funds for ordering all storage equipment for over 3 million dollars worth of spare parts. Ten of my direct reports have received promotions (1 to Electrical Engineer, 1 to supervisor, 2 to Specialists, and 6 to Team Leaders).

Job responsibility includes analyzing equipment and processes, making a decision on necessary improvements, and analytically troubleshooting technical problems. Designed and programmed new PLC/MMI automatic heating controls for production ovens. The new heating controls decreased heat tolerances, improved product consistency, and cut downtime. Project leader on several projects. Programmed and installed a vision system to automate a VFD driven capper system. The vision system eliminated an operator position. Designed and programmed a vision reject system. Developed maintenance work plans. Created job aides and helped develop preventative maintenance programs. Developed and updated electrical prints.

Collegedale, Tn

Responsible for all aspects of troubleshooting and repair of a wide range of machines. Designed and built new wrapper sealing assembly to eliminate unsealed product downtime. Planned and implemented alterations to ensure safety, to improve operator ergonomics, and to increase machine efficiency. Received hands on training in a wide range of industrial technologies. Trained other maintenance personnel and production workers in all areas. Achieved top level in this position.

Collegedale, Tn

· Monitored product quality and process control specifications at prescribed checkpoints.· Monitored equipment for malfunction and the mixing process for contamination. · Accurately following formulas to mix the ingredients. · Developed a strong understanding of food safety and quality.

Bachelors Of Science, Applied Mathematics, 3.5

Master Of Business Administration (Mba), Business, 3.9