Joseph Johnson Email & Phone Number

Rochester, Mn, Us

Rochester, Mn

Stewartville, Minnesota, United States

Responsible for leading the organization's continuous improvement strategy to improve production efficiency. Using continuous improvement methodologies, implemented a barcode labeling process converting scrapped rods into sellable product achieving $300k in additional annual profit.Advanced the lean transformation of the company by teaching lean waste and 5S to all production personnel.Implemented 5S in all production areas reducing non-value added time due to disorganization.Facilitated Kaizen (Work-Out) Events to address poor processing and packaging of fence post production resulting in elimination of customer quality complaints due to improved standard work and training.Using Solidworks, achieved $50k of annual cost savings by reducing non-value added material transportation waste by implementing an improved facility layout for Bushing and Brace storageCreated Value Stream Maps, workflow diagrams, standard work, and line balancing charts for the primary beam product line revealing improvement opportunities and executing improvement plans.Eliminated the company's highest frequency operator injury of cuts to hands and fingers by replacing razor blade scrapers with painters tools for cleaning product reducing line downtime and medical cost.

Portland, Oregon Area

Responsible for leading the lean transformation and continuous improvement initiatives across all railcar and marine barge manufacturing operations. Led the operational excellence efforts of the organization to reduce operating costs, improve quality, and reduce safety risk utilizing and educating lean and six sigma methodologies. Managed implementation of over $5M in CapEx automation and process improvement projects.Accomplishments:- Identified the business improvement opportunity, developed the solution plan, and managed the installation of a $3M fiber laser sheet metal cutting system reducing annual operating costs by $1M.- Advanced the lean transformation of the company by teaching lean methodologies, 5S+1, and root cause analysis to managers and supervisors.- Established and led the Rapid Improvement program to identify and implement lean improvements.- Managed multi-disciplinary group of supervisors, welders, electricians, quality engineers, heavy equipment material handlers, and manufacturing engineers implementing over 30 automation and efficiency improvement projects. - Utilizing Value Stream Mapping to identify current state inefficiencies, transformed railcar side panel production from push to pull process flow significantly eliminating non-value added crane and heavy equipment material handling.

Portland, Or

Designed, implemented, maintained, and improved high volume motor vehicle control system production lines utilizing LEAN manufacturing, PLC programming, one-piece flow, poka yoke, standard work, value stream mapping, OEE, and Solidworks for fixture and U-shaped cell design. Held direct collaboration with design engineers including FMEA executions to ensure production feasibility and efficiency. Accomplishments:- Led Six Sigma DMAIC projects utilizing DOE, VSM, and Capability Analysis to improve throttle sensor line profitability increasing throughput and reducing cost of poor quality by $100,000 annually.- Reduced downtime of Polaris thumb throttle line by 15% through application of LEAN principles.

Manhattan, Mt

Designed, implemented, and successfully certified company with ISO 9001 QMS.Responsible for ISO 9001 Conformance, Continuous Improvement projects, Supplier Performance, Statistical Process Control of Production, Corrective and Preventive Actions, RMAs, Internal Audits, Production Reporting, Production Cost Analysis, and Customer Satisfaction. Responsible for defining, directing, and achieving customer expectations while maintaining corporate profitability expectations

Manhattan, Mt

Redesigned and implemented an improved production floor layout for a high-volume plastic injection molding companyUtilization of Value Stream Mapping, Lean Methodologies, and AutoCAD to implement a solution that reduced changeover times from 2.5 hours to 1.5 hours, added 24 additional storage pick facings, and 16 additional mold storage spaces Reduced product and material travel distances by 45 miles/year, established a dedicated finished goods location, and created a comprehensive inventory management system

Sheridan, Wy

Eliminated production errors by establishing a work order systemImplemented BOM system to identify required amounts of material for massive ordersAssisted in implementation of ISO 9001 QMSImproved production efficiency by reducing scrap rate and implementing 5-SRedesigned the production floor layout increasing total number of work stations, improving total storage space, and reduced product and material flow distance