An experienced practitioner of Procter & Gamble's World-Class process engineering methodology. Key achievements have included:

Increased the rate on a diaper-packing machine from 21 to 34 packs/minute, whilst setting a global benchmark for reliability.
Directed a team, which reduced a diaper line size-change from 2 weeks to 8 hours
Increased the maximum rate of a core-making process from 24/minute to 35/minute, through process centre-lining and raw material changes.
Industrial Engineering

Lead a multi-disciplinary team, set up to reduce losses across 10 converting lines and their support functions. Key achievements:

Carried out a raw material balance. Discovered and challenged supplier short shipments, resulting in £4m annual saving.
Conceived and implemented a novel reject-system, reducing scrap by 70%.
Analysed raw material roll sizes versus the calculated optimum. Re-specified vendor contracts, saving £20k per annum.
Designed and installed a system to segregate tissue waste, turning worthless scrap into a valuable raw material.
Project Management

Managed projects from concept to commissioning with budgets up to $7.8mm. Experienced in all aspects of capital project management, from tender specification through purchasing, construction, commissioning, qualification and post-startup engineering. Key projects have included: -

Design, manufacture & installation of a system to control hazardous dust on 10 diaper lines. Elements of system were subsequently rolled out globally.
Concept design & implementation of new downstream packing equipment & layout for 10 diaper lines.
Performance upgrade of a waste tissue handling system, to eliminate dust & spillage.
Design & implementation of a project rollout system for use by all technical personnel across a large manufacturing site.
Plant Maintenance

Experienced in managing shift teams covering all aspects of maintaining a modern, high-speed production plant. Resources controlled have included maintenance technicians, civil contractors, cleaning contractors, stores and clerical/translation services. Set up a team of 12 technicians, carrying out planned and breakdown maintenance on 8 diaper lines. Controlled the maintenance & repair budget, focusing on reduced breakdowns and elimination of costs. Key achievements:

Conceived and implemented a planned maintenance system for a diaper plant.
Developed a program of non-destructive testing for a non-wovens welding process, eliminating unexpected failures and allowing faulty units to be replaced in planned downtime. Saving £200,000 plus downtime.
Installed automatic lubrication system on diaper lines to eliminate mechanical failures.
Reduced maintenance costs by re-evaluating spare parts prices. E.g. cost of Tucker Fingers fell from £15 to 45p, by changing supplier and manufacturing method.