Kyle Y. Johnson
Summary
Results-driven Program Manager & Quality Engineer skilled in enhancing quality and resolving technical issues across diverse teams. Successfully managed high-stakes projects that improved vehicle performance and customer satisfaction, culminating in a prestigious JD Power award.
Overview
12
12
years of professional experience
Work History
Program Manager – Quality
Stellantis
Auburn Hills
04.2025 - Current
- Drove 44% improvement in Grand Cherokee and 34% improvement in Durango bringing the programs to their best performance in program lifetime
- Contributed to securing JD Power APEAL #1 award on Durango with multiple projects leading to 18 point improvement in customer ratings
- Leading APQP & Part Readiness processes across engineering and supplier organization to deliver first time right components on time
- Oversaw quality activities of direct reports and coordinated with engineering and supplier quality teams to resolve issues
- Developed strategies to streamline customer warranty analysis, leading to faster issue resolution
- Built skilled teams to resolve issues while managing multiple challenges simultaneously
- Leading cross functional teams to resolve technical issues related to vehicle function performance and safety
Quality Plant Engineering Lead – Propulsion/EE/Mechatronics
Stellantis
Sterling Heights
01.2022 - 04.2025
- Launched Ram 1500 GMET6 engine platform, resolving 145 production assembly issues in propulsion, driveline, and rolls testing to enhance product quality
- Led team to overcome roadblocks and utilize cross functional teams and relationships to yield 22% improvements in top customer warranty issues and 14% improvement in daily FTC KPIs
- Managed team of direct reports, supporting root cause identification and corrective action implementation for specific issues to ensure effective resolutions
- Created high-level presentations to convey information and KPIs to senior leadership consistently, facilitating informed decision-making
Sr. Plant Quality Engineer – EE Wiring
Stellantis
Sterling Heights
02.2021 - 01.2022
- Lead EE Wiring Launch team and manage new content on new MY Launch, quickly identifying corrective actions, substitute parts for assembly, and creating teams to resolve issues
- Developed systematic approach for electrical warranty resolution on DT program, achieving 40% improvement in key performance indicators.
- Led cross-functional team to resolve microchip shortage issues, ensuring continuous plant operation and contributing to 10% market share growth.
- Collaborated to address critical issues, elevating RAM brand to top quality ranking and 2nd place in light-duty pickup segment.
- Review Vehicle modules to identify DTCs to develop tests to resolve top internal and external issues for launch and continuous improvement
Resident Engineer – Chassis & Brakes
FCA
Sterling Heights
09.2019 - 02.2021
- Launched Ram 1500 TRX program managing the entirety of Chassis & Brakes systems
- Engineered rear park brake and caliper technical cost reduction and process improvement, resulting in annual savings of approximately $2.5M.
- Created innovative brake vacuum tests eliminating warranty claims on specific issue and adopted as company best practice across all NAFTA plants.
- Led Cross-Functional team to resolve 30+ Top Issues for TRX Torque and Assembly Issues for TRX Launch
- Contributed to resolution of top warranty, FTC, customer complaints (CQI), and JD Power issues for DT product line, achieving highest JD Power and recent warranty score recorded.
- Team Lead backup for entire Chassis Team, from Lead responsibilities through Front End Alignment & Powertrain
Resident Engineer – BSR (NVH)
FCA
Sterling Heights
06.2018 - 09.2019
- Reviewed, identified, and resolved issues with team, leading collaboration with design engineers and suppliers to achieve $1M in Kaizen savings
- Collaborated with plant assembly, maintenance, supplier quality, and product development teams to eliminate 85+ unique issues
- Developed techniques and processes for missed torque operations, adopted company-wide for improved consistency
Industrial & Manufacturing Engineer – Future Programs – BIW
FCA
Auburn Hills
06.2017 - 06.2018
- Led Manufacturing Engineering robot station rate capability projects for Ram 1500 and Jeep Wrangler, identifying and resolving bottleneck stations, increasing production yield from 69 to 85 JPH in targeted areas
- Optimized Door Sub-Assembly stations and Hood Load for Wrangler and 1500, enabling operators to meet production rates and reducing cycle time from 75 sec to 45 sec in certain cases
- Executed ten productivity projects, achieving $300k in cost avoidance
- Developed corporate-wide fitting standard for Hoods, Doors, Tailgate for Ram 1500
Industrial & Manufacturing Engineer
KUBICA CORPORATION
Novi
01.2016 - 04.2017
- Managed thirteen projects from RFQ to implementation at manufacturing facilities, ensuring successful execution of $1.6M OEM contracts
- Delivered innovative solutions for production, material management, and quality inspection, enhancing equipment operation and technical documentation
- Designed efficient manufacturing processes to enhance production flows.
- Analyzed system performance using CAD software for optimization projects.
- Developed and implemented quality control procedures for product consistency.
Manufacturing Engineer (Internship)
LORAM MAINTENANCE OF WAY
Hamel
05.2015 - 08.2015
Manufacturing Engineer (Co-op)
Tecton Products MAINTENANCE OF WAY
Fargo
08.2014 - 05.2015
Quality Engineer (Internship)
LORAM MAINTENANCE OF WAY
Hamel
05.2014 - 08.2014
Education
Manufacturing Engineering – BS MFE -
North Dakota State University
Fargo, ND12-2015
Skills
- Risk management
- Data and KPI analysis
- Documentation and Reporting
- Change Management
- Certified Black Belt Problem Solver
- Failure analysis
- Critical Thinking
- Decision Making
- Mechanical Aptitude
- Multitasking and Organization
- Verbal and Written Communication
- Attention to Detail
Skills And Certifications
- LeadX Leadership Program
- Black Belt (Shainin Red X), 2023
- Green Belt (KT), 2020
- CAD, Creo, AutoCAD, SolidWorks
- PFMEA, 2017
- MODAPTS, 2017
Awards And Affiliations
- Sigma Alpha Epsilon Fraternity, 4 years, Executive and Philanthropy positions
- National Society of Collegiate Scholars, 4 years
- NDSU Bison Campus Tour Guide, 2 years
- NDSU Student government, 2 years
Timeline
Program Manager – Quality
Stellantis
04.2025 - Current
Quality Plant Engineering Lead – Propulsion/EE/Mechatronics
Stellantis
01.2022 - 04.2025
Sr. Plant Quality Engineer – EE Wiring
Stellantis
02.2021 - 01.2022
Resident Engineer – Chassis & Brakes
FCA
09.2019 - 02.2021
Resident Engineer – BSR (NVH)
FCA
06.2018 - 09.2019
Industrial & Manufacturing Engineer – Future Programs – BIW
FCA
06.2017 - 06.2018
Industrial & Manufacturing Engineer
KUBICA CORPORATION
01.2016 - 04.2017
Manufacturing Engineer (Internship)
LORAM MAINTENANCE OF WAY
05.2015 - 08.2015
Manufacturing Engineer (Co-op)
Tecton Products MAINTENANCE OF WAY
08.2014 - 05.2015
Quality Engineer (Internship)
LORAM MAINTENANCE OF WAY
05.2014 - 08.2014
Manufacturing Engineering – BS MFE -
North Dakota State University