Meet Neil Johnson: The Driving Force Behind Our Innovations

Meet Neil Johnson: The Driving Force Behind Our Innovations

Curious about what fuels the success of a leading foam conversion company and some of the important team members behind it?

Allow us to introduce Neil Johnson, our general manager and the rock behind some of our most innovative projects. His pivotal role in acquiring the state-of-the-art Fastweld machine—one of only two in the UK—has been a game-changer for our operations.  Learn more about Neil’s journey with over two decades of experience in the industry, Neil has cultivated a profound understanding of foam conversion processes, which fuels his drive to continually push standards and boundaries.

Join us as we delve into Neil’s impactful contributions and his ambitious vision for the future of foam conversion and fabrication as he isn’t only a manger but a mentor to many.

Describe your role?

With nearly 30 years of expertise in engineering sales and manufacturing in the non-ferrous metals and thermoplastics industries, I arrived at the factory feeling right at home.

I have a vast, varied and diverse role, from overseeing operations as the General Manager to handling production and IT to ensure that everything is running seamlessly. I’m the go-to person for anything and everything that comes our way. There are 10 different job titles on my office door, including Therapy Manager! and I can still add more, the standing joke in the office is to come into my office point at the relevant manager title and ask for them. I was given a gold start for my IT Manager skills!

What are your responsibilities?

With a workforce of over 20 personnel under my supervision, I coordinate four main teams: the prep team, responsible for material preparation, the CNC team, handling all the machining, and the finishing team. The recently added, dedicated fourth team is for a special long-term project. To effectively manage each job, the production supervisor and I use a sophisticated Gantt chart scheduling software, tracking start and end dates diligently to oversee the hundreds of customers we serve each year.

What made you get into engineering?

As with probably 99%+ of the population I didn’t end up here intentionally. From college I trained to be either an architectural or surveying technician, but the economy and life moved those goalposts to a different field. I took a sales role and found that I had a particular gift in technical sales where I excelled in adding value to products through extra manufacturing processes. Over the years this has morphed into a true engineering vocation.

What does a typical week look like?

Twice a week, I lead a comprehensive production meeting, bringing together our team leaders to review upcoming orders for the week ahead and thereafter. It’s an incredibly valuable exercise that keeps us well-informed and organised. Additionally, I generate reports for the shop floor which ensure the smooth operation of our machinery. Since covid, we’ve implemented a three-shift system, necessitating careful staffing allocation to ensure all machines are manned. In my role I oversee all the shopfloor machinery.  These include three splitters, a laminator, two auto presses, a contour cutter, three water jets, three routers, and a fast weld machine. These machines are crucial to our operations, serving the majority of our clients and projects.

What is your proudest moment at Kewell Converters?

Acquiring our state-of-the-art Fastweld machine, a project that was years in the making and a game-changer. It was something I had pushed for, as I could see the huge advantage it would give us. It’s fast, user-friendly, and consistently delivers excellent results. There are only two of its kind in the country, giving us a unique edge and expanding our range of opportunities.

What is it like to work at Kewell Converters?

Kewell is a family company and feels like a family. And many of the team members are family. I have two husband and wife teams, two brothers (Not the Kewell’s) and their cousin, and a mother and her two daughters all working here. It must be a great place to work or why else would staff be recommending working here to their loved ones.

What does quality mean at Kewell Converters?

Quality is one of the cornerstones of the Kewell ideology. It’s why many of our customers come back time and time again. We use various measures to ensure that parts we make are of the highest quality. Whether it’s taking and documenting part dimensions at every step of the manufacturing process or ensuring that all our machinery is in the very best condition. Our core values revolve around delivering exceptional quality. We strive not only to meet but exceed our customers’ expectations. Quality is our compass, guiding us in every decision and action we take.

How has Kewell Converters changed since you joined six years ago?

I’ve been here for over 6 years now, a mere blink of the eye in the grand scheme of things. But even in this timeframe I can see a big difference in materials we’re processing, the type of work we’re  undertaking and the increasing customer base. We’ll always have our roots in the Zotefoams materials, and this continues to be the bulk of the material that we process. But there has been quite a shift to new and alternative products. As a business we’re continually looking for new materials to satisfy our customer requirements. And it isn’t just materials, the way we process them is changing too with the significant investment in new technology and machinery we’re blazing a trail through the 21^st century.

And how do you think the wider industry has changed?

There have been changes to the industry. Primarily focusing on being more “Green”, as the foam industry is plagued with the plastic stigma. At Kewell Converters we’re proud of our ISO 14001 accreditation and have a huge focus on sustainability and creating reusable product protection solutions. We’re now stocking more materials with recycled content and over 50% of all waste that we generate is recycled.

How do you think the industry will change over the next decade and what challenges will this pose for those that work in it?

With a spotlight being shone ever brighter on single use plastics I should imagine that there will be a greater focus on reusable product protection solutions. We’re getting more and more customers coming to us with this brief. Whether it be military, medical or leisure related it’s everyone’s responsibility to reduce our reliance on products that are damaging to the environment. We challenge ourselves to be at the forefront of providing our customers with new, sustainable and eco-friendly materials, processes and solutions.

How would you friends describe you?

If you were to ask my friends about me, they would describe me as humorous, easy-going, caring and devilishly good looking. I enjoy putting a smile on people’s faces and creating a relaxed, enjoyable and nurtured atmosphere.

What do not many people know about you?

I have had a very chequered past. I have been a catwalk model (Seriously, I still have the photos) and danced on stage for royalty! Dance has always been a huge part of my life and have tried just about everything from Elizabethan court dancing to ballet and even clog dancing. In my early twenties I was with a group and went on a European tour taking in various venues in 6 different countries. But lets not forget that being a teenager in the late eighties and early nineties raving was king and I still have a deep affinity with Trance.

When I’m not at work, you can find me walking all over the local countryside with my cocker spaniel or relaxing in one of the local coffee shops in Edenbridge. After all, home is just a stone’s throw away from the factory. But I love to dance and never miss an opportunity to hit the dance floor. When it comes to music, I have a hugely eclectic taste, and you are just as likely to hear opera, reggae or dance music when walking past my office.

Neil’s journey in engineering has been shaped by his passion for innovation and a commitment to quality.  Our operations team have a strong background in engineering and a real passion for innovation.  They’re always on the look out for new methods and machines that optimise efficiency and enhance our foam product quality. This expertise is crucial to our commitment to providing bespoke foam solutions tailored to our clients and meet the rigorous demands of the various industries we support.

You can connect with Neil here.

Find out more from other team members including Quality Assurance Manager Geoff Daniels and meet Nick Kewell our Managing Director.