*EXPERIENCED LEAN MANUFACTURING PROFESIONAL*

Astute Lean/Continuous Improvement Director with a successful proven track record of implementation in single and multi-sites. Achieved improvements in Lead Time, Quality, Factory Layout, Process Flow, Set-Up Times, Reduced Waste, Profitability, PM/TPM and Customer satisfaction. Builds teams, improves morale and drives changes in culture. Uses metrics and visual controls, creating environments fostering accountability and responsibility. A great communicator throughout all levels of an organization and with customers. Experienced in Operations management, managing all departments: program management, customer service, manufacturing, assembly, materiel planning, receiving and shipping. Mentors and develops talent. Improves on-time delivery, quality, profitability and total customer satisfaction. Successfully worked in multi sites and traveled to work both here in the US, Australia and Europe.

AREAS OF EXPERTISE

- Lean Toolbox and Training - Continuous Improvement - Operation Management- Manufacturing Management - Program Management - Materiel Management- Kaizen/5S - Shipping and Receiving - ERP Systems and Implementation - Change Management - Staffing, Performance Reviews - Customer Presentations/Service - Goal Setting Tracking and Reporting - ISO Procedures and Auditing - Metrics and Visual Controls - People Management - Mentoring - Dealing International Basis

SELECTED ACHIEVEMENTS

Pacific Vial: Selected, Purchased and led implementation of IQMS ERP System. Introduced and implemented procedures for First Article, Non- conformance, checklists, Tie in logs and numerous other manufacturing processes. Created a 24/7 day a week working schedule.LeFiell Mfg: Using all Lean Toolbox tools, led company to UTC Supplier Gold certification and re-certification 3 years in a row. Created Work Center Safety and Operating Instructions and Visual Daily PM for 250 machines, performance metrics, improved on-time delivery to 100%, reduced cost of quality by 5%, reduced inventory, and reduced lead-time by 25%.Avibank: Using visual controls on machines, detail planning and scheduling, clear communication and daily stand up meetings, ensured manufacturing and assembly departments were able to meet aggressive weekly sales targets consistently and when required exceeded targets to help with other division weekly shortfalls. Improved productivity by 10% and reduced overtime by 5%.AMT Oxnard: Implemented department production control reports and daily stand up meetings to enable visibility of workload, priorities and correct scheduling of work. Using this system a customer program with history of late deliveries and in jeopardy of losing contract achieved consistent 100% delivery and gained customer satisfaction. Neuvant Aerospace: Conducted many Kaizen and 5S Lean Events. The major accomplishment was using Kaizen, 5S and Value Stream Mapping Lean events to turn 3 autonomous companies which all manufactured, assembled and shipped finished goods to customers in to 2 Manufacturing Facilities and 1 Assy and Shipping Facility. The 3 companies were merged in to one company umbrella. All were aerospace companies with the same/similar customer base. Working closely with our customers ensured no delivery impact of product.

Acquired were two forging companies in CA. I led a team that integrated Manufacturing Philosophies, MRP System and lean concepts in to these companies. One major achievement was leading a Set-Up Reduction Kaizen on Forge Presses. Set up times were reduced from 6 hours to 30 minutes for all forge presses. This had a significant reduction in cost, productivity and lead-times. During a year period I worked between Seattle and California.

New Programs: Bid preparation, negotiations, managing manufacturing, tooling and support departments thru to First Article Delivery and to build rate requirements. After programs made build rate they were transitioned in to normal manufacturing production support systems (MRP). Conducted monthly progress meetings both in USA and Europe. Major programs included A320 Flap Tracks for BAE in England, Floor Beam Assemblies for Bombardier in Ireland and Various components for Fairchild Dornier in Germany.Hawker De Havilland Australia: A major accomplishment achieved was after being trained by Toyota I successfully taught and implemented many Kaizen and 5S events. Assy Cells were set up for Boeing 747 Leading Edge Devices, Boeing 757 Wing Ribs, McDonnell Douglas MD80/11 Evacuation Slides and Northrop F/A18 Engine Bay Doors. The Assy Cells used Kanban Kit Pull systems from the newly formed dedicated Manufacturing Cells. The dedicated manufacturing Cells were set up paperless and used a pull system for Raw Material all the way back stream to Raw Material suppliers in USA. All support departments including; Engineering, Quality, Manufacturing Engineering, Purchasing and Shipping were incorporated in the Program Cells and the Export Program Business Unit was created. All activities accomplished were done with a good working relationship and respect of the Aerospace Unions.

20140 Village Green Drive Lakewood CA 90715Tel: 805-512-6110Email: rodger_johnston@yahoo.comLinkedIn: linkedin.com/in/rodgerj/en US Citizen

RODGER J JOHNSTON

PROFESSIONAL EXPERIENCE

Pacific Vial, Commerce 4/2015-PresentDirector, Operations ManagementResponsible from receipt of Purchase Orders to delivery of Product. Directed and managed Manufacturing, Material Management, and Shipping and Receiving departments.

Purchased and Implemented the companies first ERP System taking it from a manual labor intensive system of spreadsheets and non-linked systems.

Created and implemented a 24 hour, 7 day a week working schedule meeting all California labor laws and without overtime and major overlapping of hours.

Implementation manufacturing quality systems of First Article, Non Conformance Tags, Tie in Logs, monthly production metrics.

Supported and mentored all employees improving skills and morale. LeFiell Mfg. Santa Fe Springs 3/2008-9/2014Director, Customer Service, Continuous Improvement, Director ManufacturingAs Director of Customer Service and Continuous Improvement I was responsible from the receipt of Purchase Orders to the on-time delivery of the product, including all customer and internal reporting and all Continuous Improvement Programs and Training. Responsible for, Material Management, Shipping and Inventory Control Departments.

Improved on-time Delivery performance from 82% to 95%. Improved the accuracy of the MRPII Requirements Planning System ensuring accurate manufacturing schedule, planning and

capacity reports. This greatly assured the correct jobs were being worked, manpower planning correct and better use of overtime when required.

Led a major reduction in inventory resulting in 30% reduction in storage space required. Improved manufacturing on-time performance to dispatch reports and reduced overtime by 10%. Reduced Set-Up times on key pieces of equipment using 5S and Lean Set Up Reduction initiatives and sustained the

improvements. Created and implemented Cross Training Matrix’s for each department to visually identify training needs and enable training

plans for employees to be created. Work Center Capacity hours were added to enable shift and manpower needs. Sustained the Daily Visual PM and 5S programs. Instituted weekly department stand-up meetings with all shifts to go over 5S,

PM, Safety and departmental issues and communication.Avibank North Hollywood 8/2005 – 3/2008Manger, Ball Lok DivisionManaged Manufacturing Departments, Assembly and Production Control in meeting high rate daily delivery targets for Quick release Ball Lok fasteners for aerospace, military, marine and commercial applications. Monthly Sales of $1.9M.

With aggressive daily and weekly shipment targets was able to achieve and on many occasions exceed targets. Avibank has 3 Divisions and the Ball Lok Division was counted on to make up weekly shortfalls in sales goals of the other divisions.

Created daily priority sheets to ensure all managers understood the day’s targets and objectives. Created Hourly Visual Completed Part Target Boards for every manufacturing work center resulting in improved operator

awareness output and productivity. AMT Oxnard CA 4/2004 – 4/2005Manufacturing Operations ManagerAs Manufacturing Operations Manager at Advanced Metal Technologies I was responsible for Manufacturing Departments including Production Control, Forging, Machining, Assembly, Quality, and Shipping and Receiving for aftermarket motorcycle, car and truck wheels. Monthly Sales of $1.5M

Created Production Control Reports for all Departments to enable visibility of workload to achieve Order Requirements. Implemented Morning Stand Up meetings with all Department Managers to go over the day goals and any issues. Maintenance

would attend to be given and understand priorities. Achieved 100% Delivery compliance for a customer where poor delivery history and was in jeopardy of losing the account.

Neuvant Aerospace Corporation (Seattle WA/ Anaheim, Long Beach CA) 1995-2004Director, New ProgramsDuring my career at Neuvant Aerospace I held many Management Positions as Company needs arose. My Final Position was as Director of New Programs Responsible for 2 Program Managers co-coordinating all Start Up requirements, scheduling, tooling, manufacture and one point of contact with the customer. Other Positions: Director of Engineering and Lean (Kaizen/5S), Plant Manager - Woodinville Facility, Quality Assurance Manager, Sheet Metal Manager, AQS Manager.

PRIOR EXPIERENCE

G.U.D. Holdings Australia - Plant Manager Hawker De Havilland Australia -Manager Business Unit, Export Programs Other positions: Civil Airframes Program Manager,

Commercial Project Manager, Contract Administrator, Estimator, Aircraft Technician

TECHNOLOGY SKILLS

MS Word, Excel, MS Project, PowerPoint, MRP/ERP, IQMS ERP Systems

EDUCATION/CERTIFICATION

Certificate of Business Management. Deakin University, Melbourne Australia Australian Institute of Management – Middle Management Program. Melbourne Australia Royal Melbourne Institute of Technology – Aircraft Technician (4 years). Melbourne Australia Toyota Kaizen Training. Melbourne Australia Boeing Lean Training. Seattle Washington Delta Point - Accelerated Improvement Workshop Leader. Seattle Washington ISO Lead Auditor Training. California IQMS ERP Training and Implementation California