Restoration and building
Paul Johnson
Burton on Trent,Staffordshire
Summary
Over 35 years of experience in high-paced automotive manufacturing, specializing in Toyota Production System and continuous improvement techniques such as Kaizen. Proven ability to lead teams effectively and drive organizational change. Strong communicator with in-depth knowledge of various production areas. Committed to enhancing operational efficiency and fostering a culture of continuous improvement. Strategic Operations Manager with solid expertise in streamlining processes and driving operational efficiency. Proven track record in optimising resources, managing cross-functional teams, and implementing innovative solutions to improve productivity. Adept at fostering strong relationships with stakeholders and spearheading projects that align with organisational goals. Committed to delivering impactful results and enhancing overall business performance.
Overview
42
42
years of professional experience
Work History
Retired operations manager
none
Burton on trent, staffordshire
05.2025 - Current
Logistics
Royal Mail
burton on trent, Staffordshire
11.2024 - 04.2025
- Organized parcels for dispatch, ensuring timely delivery to customers.
Established delivery locations and optimized routes for efficiency.
Coordinated customer deliveries within planned time slots to meet expectations.
Operations Support Manager
Heidelberg Materials
01.2024 - 12.2024
- Support the area ops manager for central east, introduce standard operating procedures with the quarry manager.
- Identify gaps in performance and plan recovery strategy.
- Introduce 5S into the daily workplace train and develop all levels of the business.
Operations Manager (Value Stream Mapping)
Maier UK
02.2023 - 01.2024
- Responsible for the value stream mapping of inbound material to finished product to the customer, on time to the correct quality standard to the customers' satisfaction.
Production Manager
LEVC
Coventry
07.2018 - 12.2022
- To facilitate the daily running of the business and improve OEE, Over 100 shop floor operatives, 2 group leaders and 8 team leaders.
- To produce the product on time, to the correct quality standards in time to the customers’ requirements.
- Coordinate the logistics of goods in and the finished product out.
- The control of budgets within the department, overheads – PPE - overtime – scrap – training and development.
- Encourage continuous improvement to drive long term competitive stable employment.
- The production of the Iconic electric black London Cab.
- Increased the production by 75% over a 4 Year period.
- Established repeatable standardized work allowing auditable processes and improve training and quality results.
- Set foundation for change without impact.
- 2021 introduction of the electric VN5 Van.
Production Manager
Kautex / Unipart
Coventry
01.2018 - 07.2018
- Ran a shift of Injection / blow molders to produce fuel tanks and subsidiary components for tier 1 supply.
- Accountable for all KPIs being achieved and the daily operations of the shift reporting back to the factory manager daily.
- Introduction of Process design, People management and Problem solving techniques.
Group Leader Senior – Assembly Shop
Toyota Motor Manufacturing UK Ltd
Burnaston
01.1994 - 01.2018
- Responsible for the management of the group building all models built at the Burnaston facility.
- Accountable for the day to day supervision of 50 employees including 6 team leaders.
- Completed 9 years operation without any accidents in the area.
- Achieved the Key Performance Indicator for Safety Awareness Points of 60 per month.
- Achieved a Companywide safety award for eliminating trap hazards in area.
- Production targets achieved or exceeded of 95% per shift on a regular basis.
- Introduced an abnormality tracking system to identify potential concerns and instigate counter measure activity.
- Managed a change in the build process to reduce cost by the reduction of in-process stock saving the company £22,000 per year.
- Lead global chassis project - to communize vehicle capability in any plant.
- Toyota is the world's largest manufacturer. The site at Burnaston builds the Toyota Auris, the new Hybrid and is the sole production centre for the Toyota Avensis.
Operative
Durapipe Ltd
Burntwood
01.1993 - 01.1994
- In charge of keeping the machinery running, ensuring the quality of the product, communicating loss of productivity, breakdowns to the supervisor.
Departmental Supervisor
Elkes Biscuits Ltd
Uttoxeter
01.1986 - 01.1993
- To ensure that the production line ran to the best of its ability.
- Responsible for the daily supervision of the workforce.
- Managing stock levels and placing orders as necessary.
- Manufacturer of biscuits for the Northern Foods Group.
Mechanic
D G Russells Car and Commercial Garage
01.1984 - 01.1986
- To repair vehicles and maintain the vehicles to the requirements of the customer.
- Local garage.
Education
College Diploma - Management, level 3 engineering, IOSH Safety, Mental health First aider, Motor vehicle technician Certificates
Skills
- Toyota Production System
- Lean manufacturing and Kaizen
- Just-in-time delivery
- Health and safety compliance
- Environmental awareness
- Leadership skills
- Presentation development
- Coaching and communication
- Work planning and prioritization
- Problem-solving techniques
- Microsoft Office proficiency
- BMS systems expertise
- ISO documentation management
- Logistics coordination
- Operations management
- Value stream mapping
- Continuous improvement
- Budget control
- Process design
- Quality assurance
- Team leadership
- Performance analysis
- Risk management
- Customer service
- Supply chain management
- Employee training
- Problem solving
- Safety compliance
- Project logistics coordination
- Production logistics familiarity
Custom Section
Six Sigma - Foundation, Green Belt, Black Belt, Managing your team's well-being, Managing logistics, Manager who fights for his team, Mental Health First Aider, HV Level 2 Trained, NEBSM Diploma in Supervisory Management, Emotional Intelligence, Leadership Modules 1 – 3, NVQ 2 BIT (Business Improvement Techniques), NVQ 3 Engineering Leadership, City and Guilds Motor Vehicle Mechanics, IOSH Managing Safety, ACAS Trained Managing People, Continuous Professional Development as part of the Toyota training programme
Personal Information
Relocation: Full clean driving licence with own transport
References
Available on request.
Hobbies and Interests
Currently building a two storey extension to the house and landscaping the garden.
Interests
Timeline
Retired operations manager
none
05.2025 - Current
Logistics
Royal Mail
11.2024 - 04.2025
Operations Support Manager
Heidelberg Materials
01.2024 - 12.2024
Operations Manager (Value Stream Mapping)
Maier UK
02.2023 - 01.2024
Production Manager
LEVC
07.2018 - 12.2022
Production Manager
Kautex / Unipart
01.2018 - 07.2018
Group Leader Senior – Assembly Shop
Toyota Motor Manufacturing UK Ltd
01.1994 - 01.2018
Operative
Durapipe Ltd
01.1993 - 01.1994
Departmental Supervisor
Elkes Biscuits Ltd
01.1986 - 01.1993
Mechanic
D G Russells Car and Commercial Garage
01.1984 - 01.1986