Joseph Todd Metcalf
Shelbyville
Summary
Results-driven Manufacturing Manager and Continuous Improvement Trainer with over 35 years of experience leading production operations, process improvement, and team development within the automotive and metal manufacturing industries. Proven ability to enhance safety, quality, and throughput by implementing Lean Manufacturing principles and Six Sigma methodologies. Strong communicator who builds empowered, safety-focused teams and drives measurable improvements in efficiency, cost reduction, and product quality.
Overview
37
37
years of professional experience
1
1
Certification
Work History
Manufacturing Manager & Continuous Improvement Trainer
Topy America
Frankfort
10.2023 - Current
- Lead off-shift manufacturing operations for a major automotive wheel supplier.
- Directly oversee safety, quality, and production performance while developing employees through Lean and standardized work practices.
- Key Achievements:
- - Improved line performance and reduced scrap through daily process confirmation and operator training.
- - Partnered with engineering and maintenance teams to enhance equipment reliability and minimize downtime.
- - Streamlined onboarding and training processes to fully staff and stabilize production teams.
Production Consultant (Contract)
Purem by Eberspächer
Louisville
02.2023 - 09.2023
- Contracted to ramp up production operations to meet startup deadlines for Ford Motor Company's SOP schedule.
- Key Achievements:
- - Accelerated line readiness and workforce capability to meet aggressive production targets.
- - Coordinated with Ford quality and logistics teams to ensure on-time delivery of launch components.
Operations Manager
Hussey Copper
Eminence
07.2021 - 10.2022
- Oversaw plant operations and workforce performance for a copper manufacturing facility.
- Implemented Lean practices and safety programs to drive productivity and compliance.
- Key Achievements:
- - Introduced Lean Manufacturing and 6S initiatives across departments using MOS boards.
- - Improved safety compliance and PPE adherence through targeted training and accountability.
- - Supported new equipment ramp-up while meeting daily production targets.
Continuous Improvement & Launch Manager
Lear Corporation
Louisville
04.2020 - 07.2021
- Developed and led Lean initiatives and supported launch operations for automotive seat production.
- (Seating Division)
- Key Achievements:
- - Led kaizen projects to reduce waste and improve production flow.
- - Partnered with engineering to validate new seat designs and launch successful trial runs for OEM clients.
Production Supervisor / Manufacturing Lead
Magna Seating
Shepherdsville
03.2019 - 04.2020
- Directed daily production operations in a high-volume automotive seating facility supporting OEM contracts.
- Key Achievements:
- - Improved team efficiency and adherence to standardized work processes.
- - Supported continuous improvement projects to enhance safety and throughput.
Senior Process Coach / Process Coach
Ford Motor Company
Louisville
06.1989 - 02.2019
- Provided leadership and direction to production teams in one of Ford's largest assembly operations.
- Focused on standardization, safety, and quality improvement initiatives.
- (Louisville Assembly Plant)
- Key Achievements:
- - Coached teams to consistently meet FTT, scrap, and tooling cost targets.
- - Reduced downtime through proactive monitoring of ANDON calls and process confirmations.
- - Trained team leaders and operators on Lean, 5S, and Continuous Improvement methods.
Education
Some College (No Degree) - Criminal Justice
University of Louisville
Louisville, KYSkills
- Automotive Manufacturing Leadership
- Lean Manufacturing
- Six Sigma
- Continuous Improvement
- Kaizen
- 5S
- MOS
- Team Building
- Training
- Safety
- Quality Assurance
- Production Planning
- Scheduling
- Budget Control
- Cost Control
- Process Optimization
- Root Cause Analysis
- Problem Solving
- Cross-Functional Collaboration
Certification
- Six Sigma / Lean Manufacturing
- 5S & Visual Factory
- ECPL Lockout / Tagout
- Continuous Improvement & Throughput Awareness
- Integrity and Leadership Development
References
Available upon request
Timeline
Manufacturing Manager & Continuous Improvement Trainer
Topy America
10.2023 - Current
Production Consultant (Contract)
Purem by Eberspächer
02.2023 - 09.2023
Operations Manager
Hussey Copper
07.2021 - 10.2022
Continuous Improvement & Launch Manager
Lear Corporation
04.2020 - 07.2021
Production Supervisor / Manufacturing Lead
Magna Seating
03.2019 - 04.2020
Senior Process Coach / Process Coach
Ford Motor Company
06.1989 - 02.2019
Some College (No Degree) - Criminal Justice
University of Louisville