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


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.


  • Mike Johnson Associates Ltd.

    2014 - Current
    Mike Johnson Associates Ltd.
  • 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.


MBA - Lancaster University

Fellowship in Manufacturing Management - Cranfield University

BSc (Hons) Electrical Engineering - Salford University

Certified Belbin Assessor

Interests and Hobbies



Email Mike

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