Keith Johnson is the Founder and CEO of J & A International and LEAN TPM Consulting Group. He is an accomplished and highly effective Senior Business Transformation Executive with the ability to motivate multi-disciplined, cross-functional and multi-cultural teams to achieve Operational Excellence through driving Continuous Improvement, using the Toyota Production System, Six Sigma and Theory of Constraints (TOC).
This passionate and determined leader demonstrates polished communication skills and natural authority, and benefits from exceptional performance and transformational change abilities which have been proved in structured corporate environments with over $100 million in cost savings.
With an enviable track record of defining and delivering innovative strategies that address the needs of all stakeholders, this qualified Lean Six Sigma Master Black Belt has a wealth of experience working with companies covering a vast array of industries, integrating industrial engineering expertise to effectively drive results, and will be an asset to the Board or senior management team of any forward thinking organization.
PAPERS
The Need for Trust in Lean Transformation – By Keith Johnson
SKILLS
Organizational Leadership
Visionary leadership and skilled resource allocation delivering improved efficiency
TQM Quality Management
Thorough and systematic implementation of highly efficient quality procedures
Operational Excellence
Attains sustainable, progressive improvement of diverse corporate operations
Process improvement
Achieves Operational Excellence with Lean Management, 5S, and Six Sigma methods
Strategy and Planning
Defines and directs the implementation of innovative and successful strategies
Change Management
Manages process and culture change with minimal disruption to core activities
Profit Maximization
Achieves maximum profits through diligent cost control and revenue generation
Lean Methodology
Utilizes accredited Lean methodology technical tools to transform businesses
Problem Solving
Incisive investigation, Root Cause Analysis and corrective action implementation
Team Leadership
Strong, decisive leadership of diverse cross-functional and multi-cultural teams
Sales Management
Develops and manages strategic partnerships to maximize sales opportunities
Project Management
Proven ability to lead complex projects from concept to successful completion
Coaching & Development
Leads teams to develop and implement LEAN process improvement practices
Compliance FMEA, Control Plan, APQP, SPC, DOE, MSA, PPAP, Capability Analysis, ISO 9000/QS 9000/TS 16949 Quality Systems
Value Stream Mapping, Statistical Process Control, Design of Experiments, Automotive Quality , Supply Chain Management, Source Inspection, Quality System Audits/Surveys, Product Development, Advanced
Product Quality Planning, Global Fitness for Use, New Product Introduction (NPI)
EDUCATION AND TRAINING
Certified Shingo Examiner
Utah State 2007
Six Sigma Black Belt Training
Villanova University 2005
Trained by disciples of Shigeo Shingo (TPS)and Eliyahu M. Goldratt (TOC)
1994
Master of Human Resource Development
Clemson University 1993
BS in Industrial Management
Georgia Institute of Technology 1980
KEY STRENGTHS AND SELECTED ACHIEVMENTS
- LEANTOC: Lean Six Sigma Transformation by Waste and Variation Reduction through Systems Thinking and Constraint Management
- LEANTPM: Optimizing and Integrating People and Machines through Total Productive Maintenance
- Drove margins to over 35% and on-time delivery to 100% through inventory reduction and productivity increases saving over $4.5 million to the bottom line for US and Mexico operations in less than 12 months
- Saved over $3 million through reducing inventory ($2.3 million), defects 60%, improved process capability 80%, and on-time delivery to 99.94% from 92% for rubber mixing and performance additives company
- Achieved $250,000 savings in 5 days for Chinese client leading 14 engineers to reduce set up times by 75% and balancing assembly cells to meet takt time
- Led USAF team to transform 650 employee repair/rebuild shop into a leaner, more agile organization through flow day reduction, rework reduction, standard work, visual workplace, VSM and set up reduction
- Implemented one-piece flow resulting in 38% WIP reduction, $169,000 direct labor savings, 45% efficiency increase and 78% floor space reduction
CAREER HISTORY
October 1994 – present J & A International, Inc., Seneca, SC
Integrating people and technology for high performance by empowering people to work effectively with complex technology through strategic planning, needs assessment, re-engineering for lean systems, results-oriented training and evaluation methods. www.leantoc.com
Master Black Belt Turnaround Expert
Managing Director of a management consultancy firm providing business transformation services based on the principles of Proactive and Preventative Maintenance with the tools and philosophy of the Toyota Production System to get bottom line results for clients.
Illustrative Projects
Georgia Pacific Chemicals – Managed projects in 14 paper chemical plants throughout the US to develop quality systems and drive bottom line results through Lean Six Sigma.
Kroger Foods – Led 34 plant implementations in Total Productive Maintenance and Lean flow and SPC; plants included Dairy, Bakery, Salsa, Jams, Bottled Water, Salad Dressing, Soft Drinks
Chevron Nigeria, Lagos, Nigeria – Conducted Train-the-Trainer workshop and implemented Total Productive Maintenance, Facilities Maintenance, 5S and Energy Management Assessment for a 600 person compound.
Stanadyne – Implemented one-piece flow cells in 2 sites reducing WIP by $1 million, headcount by 20%, floor space by 80%, travel distance by 89%, while increasing productivity by 10%.
USAF 328th Armament Systems Wing – Led plating shop improvements at Eglin AFB/ Tyndale AFB – Ft Walton Beach, Panama City, FL; led Kaizen teams reducing total cycle time by over 50% for various business and manufacturing processes resulting in annual savings of over $500,000 for the DOD (Targets, AMRAAM and Foreign Missile Sales)
Parker Hannifin (Mexico and USA) – Total savings of over $4 Million in productivity (35% increase) and inventory (60% decrease in WIP and 260% increase in WIP turns) through SMED, one-piece flow and TOC.
Hexagon Polymers Compounding – Rubber Mixing Chemicals for 8 plants in Quebec, Belgium, Czech Republic, Sweden, Germany, USA; led North American and European Presidents, VPs and Directors to strategically design sales plan and Business Operating Systems to increase EBIT by 30%. Implemented a world class business system in Quebec facility resulting in over $1 million in annualized savings in 4 months. (Efficiency up 30%, set up time down 30%, scrap down 40%)
Owens Corning, USA, Belgium – Implemented Global Fitness For Use (QFD) worldwide resulting in innovative and world class products with shorter design times.
Fuji Photo Film –Total Productive Maintenance, Maintenance Scheduling, 5S and energy management.
Ryobi Power Tool Group – Implemented ISO 9001 at a 1500 employee division in 10 months reducing inspectors by 50% and increasing sales by 30%.
Emerson Electric, Schenzen, China – Conducted and directed Kaizen Events reducing Setup time by 75% on bottleneck resulting in $250,000 savings.
Dominion Semiconductor, Robert Bosch, Amoco, Kaiser, Torrington – Trained and implemented ISO/QS 9000, Internal Auditing, APQP, FMEA, Control Plan, PPAP, 8D Problem Solving and SPC.
Thailand Auto Alliance (Ford/Mazda), Thailand – Trained suppliers in QS 9000, 8D Problem Solving, SPC, MSA and Mistake Proofing.