Mike Johnson

Director

Business Consultant

Manchester

+6 more

Cheshire
Chester
Lancashire
Leeds
Liverpool
United Kingdom

Willem Carstens - Senior Manager Sasol / Director High Capacity Output Mike was initially a consultant supplying services to my business and is now a...

- Willem Carstens, May 2017

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Expertise

Operational Excellence
Business Consultancy
Programme Management
Project Management
Change Management
Lean Manufacturing
Business Process Engineering
Continuous Improvement

Summary

I am a seasoned Consultant with 16 years’ experience in delivering results through diagnosis, planning and execution across a range of industries. My career path has been though Engineering Management, Production / Factory Management and Consultancy. I have been privileged to learn from excellent institutions, colleagues and Client organisations.

My assignments have necessitated working at all levels and functions within businesses, delivering a range of services that are bundled into the Operational Excellence, Lean, Six Sigma and Continuous Improvement suite of improvement methodologies.

During projects, I have mentored and coached individuals, developing internal consultants and managers, together with teams, to deliver meaningful results and significant cost improvements.

I have worked in many geographical locations including international assignments in USA, Canada, Russia, China, Germany, France, Switzerland, Norway, Azerbaijan and several years in South Africa. I have worked with a wide range of Blue Chip and SME clients engaged in discrete manufacturing, Paper Production, Oil and Gas, Chemicals, Petrochemicals and Steel Processing.

I know the difficulties in driving growth and improvement in a business environment and I understand what it takes to assist you in successfully delivering results.

Experience

Mike Johnson Associates Ltd.

Director
2014 - Current
ABB (Forrmerly ICI Eutech)

Principal Lead Consultant
100+ Employees 2000 - 2014

Key Achievements Include:
International Petrochemical Company based in South Africa
• Led an ABB and Client Team varying in size between 5 and 15 consultants
• Developed an Operations Excellence model and methodology with the client
• Trained, coached and mentored the client Operations Excellence internal team - developing them to deliver benchmarking and improvement
• Delivered consultancy at shop floor, middle and senior management levels
• Delivered audited benefits more than $500m

Within ABB
• Delivered the analysis and “case for change” for relocation of business operations to low cost countries
• Strategically re-engineered a US business producing specialist instrumentation which was losing more than $1m annually using lean methodologies and intelligent outsourcing. The plant has been delivering profits for several years and runs at an EBIT of more than 15%.

Within Process industries
• Paper industry - Delivered financial benefits in excess of £2m through Manufacturing Improvement Teams (MITs) focused on areas of loss, identified in an OEE base lining exercise, for a major Board manufacturer. Machine throughput improved by a conservative 8%.
• Steel industry – Reduced waste by more than £500k annually on a process line in a sustainable manner, using an MIT
• Paper industry – Increased throughput by more than 60% on a packaging line. Reduced paper machine costs by £2m.

International assignments in USA, Canada, Russia, China, Germany, France, Switzerland, Norway, South Africa, Azerbaijan
Bibby and Baron Limited

Production Manager
100+ Employees 1995 - 1998

Responsible for producing more than 7.5m printed paper bags per week for major retail customers including M&S, Tesco and Asda.
Key Achievements include: -
• Increase in throughput averaging 8% and reduction in customer returns to significantly less than 0.01 %.
• Progression of team working within the department, across departments and into the supply chain.
• The successful onsite integration of a £6m turnover, 100 employee acquired competitor.
• The continuation of customer focused performance improvement, through the inevitable disruption caused by changes in ownership in a heavily unionised environment.
The Amtico Co.Ltd,

Factory Manager
100+ Employees 1993 - 1994

• Responsible for cellular operation, producing luxury vinyl floor tiles for UK and international markets. The company operated JIT with an order book typically less than 4 days.
Key Achievements include: -
• Throughput increased by 27% to meet market demand, OTIF > 97%
• Quality improved with complaints at minimal levels - Less than 1 part per million
• Introduction of a capacity planning system and kanban stocks
• The commissioning of online equipment to reduce batch processing, reduce changeover times and increase plant flexibility.
James Cropper PLC

Electrical Engineer
100+ Employees 1984 - 1991

Responsible for managing the Electrical Department of the Paper Mill, including project and maintenance work.
Key Achievements include: -
• Managed Projects valued at more than £30m including, (CHP) Plant, 3 Paper Machine rebuilds with fast changeover characteristics, finishing department rebuild, design & construction of onsite subsidiary and a JV located in Germany
Courtaulds

Electrical Engineer
1982 - 1984

• Responsible for a team of providing an electrical maintenance service to the factory.
Key Achievements include: -
• The introduction of variable speed spinning which enabled throughput to increase by 6%
Courtaulds

Student Electrical Engineer
100+ Employees 1976 - 1984

• Studied Electrical Engineering with industrial training periods at sites within the Courtaulds Group before taking the position of Assistant Electrical Engineer at the Trafford Park works.