Robert E. Johnson Email & Phone Number

Novi, Mi, Us

Livonia, Mi

North America Leader for Pallecon and Automotive Solution's Quality Systems, Zero Harm Safety Program and Regulatory Affairs.• Achieved and exceeded Zero Harm Safety initiatives for FY 15 and FY18, lowering lost time injury rate 100% and increasing Near Miss and First Aid Treatment reporting by 50% YOY• Project manager for ISO 9001:2015 certification- achieved certification April 2019• Led TQM for all Corporate and SCs incorporating SOPs and WIs as needed , providing on-site… Show more North America Leader for Pallecon and Automotive Solution's Quality Systems, Zero Harm Safety Program and Regulatory Affairs.• Achieved and exceeded Zero Harm Safety initiatives for FY 15 and FY18, lowering lost time injury rate 100% and increasing Near Miss and First Aid Treatment reporting by 50% YOY• Project manager for ISO 9001:2015 certification- achieved certification April 2019• Led TQM for all Corporate and SCs incorporating SOPs and WIs as needed , providing on-site training and support• Project managed SOAPY to harmonize all corporate and SC SOPs and Work Instructions, creating a transparent central intranet source for entire organization to access• Operations Cost Savings Initiatives, FY15 and FY18 savings in excess of $500,000 annually Show less

Livonia, Mi

Champion of safety, quality, production, logistics, planning, and transportation metrics for 9 Service Center locations. Partnered with 3rd party labor, dedicated, and OTR party brokered carriers, utilizing CHEP corporate support to provide over 200 customers fulfillment of 6.2M assets annually.• Successfully managed daily production and shipping scheduling utilizing lean tools, including sister company Lean Logistics, realizing optimal dock and carrier utilization while meeting or… Show more Champion of safety, quality, production, logistics, planning, and transportation metrics for 9 Service Center locations. Partnered with 3rd party labor, dedicated, and OTR party brokered carriers, utilizing CHEP corporate support to provide over 200 customers fulfillment of 6.2M assets annually.• Successfully managed daily production and shipping scheduling utilizing lean tools, including sister company Lean Logistics, realizing optimal dock and carrier utilization while meeting or exceeding Key Performance Indicators• Spearheaded multiple Kaizen events continuously improving processes from cradle to grave• Led cross-functional project management/mapping teams implementing plant start ups, plant closures, and 3rd party labor transitions, while seamlessly fulfilling customer needs• Exceptional team member of Central Team realizing $3.9M cost savings from 2009-2014• Listened, collaborated, and delivered to CHEP USA strategic customer-centric initiatives assuring quality conformance and total customer satisfaction Show less

Livonia, Mi

Managed Total Quality System and customer-centric activities at the Livonia, MI pallet Service Center, pulling quality Process Control Plan (PCP) through to our customers.•Directed implementation of Quality PCP and Standard Work processes pulling quality through to customers•Performed contractually required asset quality audits, providing corrective actions and chargeback to 3rd party labor as necessary generating 18K annually•Developed and implemented 2 Kaizen improvement events… Show more Managed Total Quality System and customer-centric activities at the Livonia, MI pallet Service Center, pulling quality Process Control Plan (PCP) through to our customers.•Directed implementation of Quality PCP and Standard Work processes pulling quality through to customers•Performed contractually required asset quality audits, providing corrective actions and chargeback to 3rd party labor as necessary generating 18K annually•Developed and implemented 2 Kaizen improvement events, collaborating with 3 CHEP departments and 3rd party labor, reducing rejected and returned loads from 3% to 0.018% of total issues saving 78K annually•Partnered with 3rd party labor, 3 CHEP departments, and high profile customers visiting customer sites investigating and resolving quality and delivery non-conformances including Pepsi Cola, Coca Cola, Nestle, Campbell’s Soup, Con Agra, P&G, Hillshire Farms, Absopure Water, Pinnacle Foods, Wal-Mart, Sam’s Club, Costco, Meijer, and Sysco Foods Show less

Wixom, Mi

Executed Corporate QC/QA process for 3 sites providing FDA compliant end user kidney dialysis concentrates. Reported directly to President, CEO and CFO.• Reduced start up plant process and product design control validation implementation to 10 days from 30 days-cost savings of $20K • Reduced corporate non-conformances by 20% through cross-functional focus groups utilizing Kaizen/Lean manufacturing tools • Harmonized corporate and site SOPs, eliminating non-value added activity… Show more Executed Corporate QC/QA process for 3 sites providing FDA compliant end user kidney dialysis concentrates. Reported directly to President, CEO and CFO.• Reduced start up plant process and product design control validation implementation to 10 days from 30 days-cost savings of $20K • Reduced corporate non-conformances by 20% through cross-functional focus groups utilizing Kaizen/Lean manufacturing tools • Harmonized corporate and site SOPs, eliminating non-value added activity while increasing QC lab efficiency by 10% • Eliminated raw material incoming QC testing based on excellent history of suppliers, trend analysis, and C of A verification-annual cost savings of $5200 • Eliminated redundant finished product in-process sampling and testing, increasing lab throughput by 25% while reducing overtime to zero-cost savings of $ 25K annually Show less

Ypsilanti, Mi

Executed Total Quality Management (TQM) for 2 sites of plastic container manufacturing, reporting directly to CEO.•Lead Quality representative for IQMS ERP software mapping and quality module implementation, increasing QC efficiency by 30% enabling elimination of 1 head count saving $35K annually•Utilized Lean and Six Sigma tools to eliminate non-value added activities, increase efficiency by 20% and reduced batch record review/release from 7 days to 48 hours•Developed and… Show more Executed Total Quality Management (TQM) for 2 sites of plastic container manufacturing, reporting directly to CEO.•Lead Quality representative for IQMS ERP software mapping and quality module implementation, increasing QC efficiency by 30% enabling elimination of 1 head count saving $35K annually•Utilized Lean and Six Sigma tools to eliminate non-value added activities, increase efficiency by 20% and reduced batch record review/release from 7 days to 48 hours•Developed and implemented SOP training metrics for two sites decreasing new hire training time by 50%•Reduced incoming raw material inspection and testing by 90% by developing Supplier Qualification process reducing testing based on historical supplier trend data-cost savings of $10K annually•Quality point person on Lean Manufacturing team achieving corporate goals by increasing annual inventory turns from 8 to 17/mo., increased on time delivery to 97% + from 75%, decreased production lead times from 8 weeks to 10 days, and decreased mold changes from 10 hours to 1-2 hours utilizing SMED, 5S, 7 wastes, Kanban, and Kaizen methodologies Show less