JOHNNY FOSTER
Findlay,Ohio
Summary
To secure a Managerial position with a company that can utilize my experience in a collective and committed effort to becoming or sustaining world-class operations and culture.
Highly motivated, career oriented, success minded, professional, who is a hands-on leader with twenty-five plus (30+) years of extensive experience in operations management, project management and waste reduction / lean concepts in the fast-paced Tier 1 automotive industry, competitive plastic and overlaminate industries. Demonstrated ability in leadership, mentoring, direction, scheduling priorities and implementing new projects with-in budget and established timelines.
Overview
27
27
years of professional experience
Work History
Area Manager
Teijin Automotive
06.2023 - Current
- Daily activities of forty (100+) union employees, currently two (2) Shift production operations of custom molding operation supplying the automotive and commercial truck industry
- Ensure adherence to the established Company policies and guidelines to include the Employee Handbook
- Review safety and quality concerns with supervisors and quality team
- Work with Supervisor on conducting daily 5S audits
- Work with Supervisor of preparing daily production runs
- Review production plans with Supervisors to ensure daily shipment are completely
- Developed and implemented scheduling process to maximize efficiencies of weekly production output
- Developed and implemented 5S program, to eliminate dirt, dust and debris
- Work with the quality team and implemented quality audit process
Operations Manager
ACPO
06.2018 - Current
- Daily activities of fifty-two (52) non-union employees, three (3) Shift production operations of the Coating, Converting and Warehousing Departments supplying over-laminate to Customers throughout the United States, Europe and South America
- Daily activities, coaching and mentoring of Five (5) Shift Supervisors
- Ensure adherence to the established Company policies and guidelines to include the Employee Handbook
- Ensure compliance for all necessary legal and regulatory documents
- Training, Production, Quality and Customer Delivery requirements for the Coating, Converting and Warehousing Departments
- Manage all costs including labor, general expenses, and supporting internal allocations that effect overall Department P&L reports
- Manage annual Labor Budget of four (4) million dollars
- Manage annual Expense Budget of Two (2) million dollars
- Manage, develop and track yearly budgets in relation to projected volume of materials procured and other fiscal goals
- SQCDM KPI Metrics (Safety, Quality, Cost, Delivery, Manpower)
- Continuous Improvement Initiatives Utilizing Lean Management concepts
- TQM processes and principles
- Overall increase in first run capability from 60% to 80%
- Reduction of customer quality claims from an average of three (3) per month to one (1) per quarter
- Raised on-time delivery of Customer orders from 80% to 95% OTD
Plant Manager
Laminate Technologies
06.2020 - 06.2023
- Daily activities of fifty-two (105) non-union employees, three (2) Shift production operations of the Laminate, Fab and Warehousing Departments supplying over-laminate and fabrication to customers throughout the United States
- Daily activities, coaching and mentoring of three (3) Shift Supervisors
- Ensure adherence to the established Company policies and guidelines to include the Employee Handbook
- Ensure compliance for all necessary legal and regulatory documents
- Training, Production, Quality and Customer Delivery requirements for the Lamination, Fabrication and Warehousing Departments
- Manage all costs including labor, general expenses, and supporting internal allocations that effect overall Department P&L reports
- Manage annual Labor Budget
- Manage annual Expense Budget
- Manage, develop and track yearly budgets in relation to projected volume of materials procured and other fiscal goals
Coating Manager
ACPO
12.2012 - 06.2018
- Daily activities of twenty-two (22) non-union employees, three (3) Shift production operations of the Coating, Converting and Warehousing Departments supplying over-laminate to Customers throughout the United States, Europe and South America
- Daily activities, coaching and mentoring of three (3) Shift Supervisors
- Ensure adherence to the established Company policies and guidelines to include the Employee Handbook
- Ensure compliance for all necessary legal and regulatory documents
- Training, Production, Quality and Customer Delivery requirements for the Coating, Converting and Warehousing Departments
- Manage all costs including labor, general expenses, and supporting internal allocations that effect overall Department P&L reports
- Manage annual Labor Budget of two (2) million dollars
- Manage annual Expense Budget of one (1) million dollars
- SQCDM KPI Metrics (Safety, Quality, Cost, Delivery, Manpower)
- Continuous Improvement Initiatives Utilizing Lean Management concepts
- Developed and implemented comprehension daily quality checks to ensure adherence to established standards
- Implemented 5S program for both Lamination and Fabrication Department
- Implemented glue rotation program
- Implemented formal Kan Ban inventory process to proactively service Customer orders
Operations Superintendent
Centrex Plastic
06.2008 - 12.2012
- Daily activities of forty (40) non-union employees, two (2) Shift production operations of custom injection molding operation supplying the automotive and commercial truck industry
- Ensure compliance with established procedures and processes to include Employee Handbook
- Review safety and quality concerns with supervisors and quality staff
- Work with Supervisor on conducting daily 5S audits
- Prepared manpower for daily production runs
- Review production plans with Supervisors to ensure daily shipment are completely
- Developed and implemented scheduling process to maximize efficiencies of molding operation
- Developed and implemented 5S program
- Developed and implemented quality audit process
Assistant Manager
Nissin Brake Ohio
07.2004 - 06.2008
- Assisted in the management of the daily activities of 320 non-union employees, three (3) Shift production operations of the Assembly Department supplying Honda brake systems and Harley Davidson motorcycle parts
- Eight (8) Supervisors, Fifteen (15) Process Engineers and one (1) Technical Coordinator
- Engineering, Training, Production, Quality and Customer Delivery requirements for Assembly Department
- Review safety and quality concerns with supervisors and quality staff
- Work with supervisor on conducting daily 5S audits
- Development of program launches and new program development
- Implementation of project oriented initiatives geared toward lean initiatives, waste reduction and process improvements
- Increase in overall 1st run capability from 75% to 85% for all assembly lines
- Decrease in overall defect rate of 8% to 2% over a four month (4) span resulting in an annual savings of $250,000
Superintendent
Nissin Brake Ohio
07.1997 - 07.2004
- Supported the activities of six (6) Production Supervisors
- Review safety and quality concerns with Supervisors, Line Leaders and Quality Staff
- Work with Supervisors on conducting daily 5S audits
- Prepared manpower for daily production run
- Review production plans with Supervisors to ensure daily shipment are completed
- Coordinate with Maintenance Department to ensure all work centers are running properly and to standard cycle time, as well as ensuring priority presses are repaired first
- Responsible for overseeing plant operation for 3rd Shift of four (4) Manufacturing Departments (Machining, Casting, Assembly and NK21 building)
Education
Business/Marketing Management Major -
Arkansas Tech University
Russellville, ArkansasSkills
- Staff Management
- Operations Management
- Relationship building and management
- Team Development
- Goals and performance
- Performance Management
- Operations
References
Available upon request
Timeline
Area Manager
Teijin Automotive
06.2023 - Current
Plant Manager
Laminate Technologies
06.2020 - 06.2023
Operations Manager
ACPO
06.2018 - Current
Coating Manager
ACPO
12.2012 - 06.2018
Operations Superintendent
Centrex Plastic
06.2008 - 12.2012
Assistant Manager
Nissin Brake Ohio
07.2004 - 06.2008
Superintendent
Nissin Brake Ohio
07.1997 - 07.2004
Business/Marketing Management Major -
Arkansas Tech University
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