A very reliable, experienced Production/Manufacturing Manager who has developed and honed inter personal skills to a high level. A coach, mentor and advisor to his teams and colleagues. A strong engineering background has developed effective continuous improvement methodology combined with logical thinking, problem solving and root cause analysis skills. Education in lean manufacturing from Japanese instructors has seen the effective use of 5S, Kanban, Kaizen etc utilised to eliminate all types of waste on pull systems and single piece flow processes. Capable of improving processes by researching, analysing, reducing and controlling variation. Competent and confident in the use of six sigma and World Class Manufacturing autonomous maintenance tools and techniques. Now pursuing a challenging role in a progressive and lean thinking organisation.

KEY SKILLS

• Leadership: relationship builder, communicator, facilitator, motivator and influencer, catalyst for change, provider of encouragement. transformational leadership styles.
• People Development: coach, mentor, advisor and trainer, conflict manager, achievement recognition
• Production Management: manufacturing process developer and improver, Continuous Improvement, Lean thinking, 6 sigma, World Class Manufacturing, 5S, Kaizen, Kanban, FIFO
• Analyst: problem solver, process understanding, special cause variation reduction and elimination, facilitator
• Communicator: balance of styles, driver, analytic, expressive and relator,
• Relationship Management: builder of trust, understanding, compassion, respect, integrity, credibility, recognition and reward
• Business development: process improver, waste reduction, cost reduction, profit maximisation.
• Engineering: time served Instrumentation and Control engineer, researcher, trouble shooter, fault finder.

EMPLOYMENT HISTORY

British Gypsum, East Leake, Leicestershire Feb 2005 to Present

UK market leader in gypsum plaster and plasterboard systems, British Gypsum is a subsidiary of BPB plc, the world's largest producer of gypsum-based building materials with a presence in over 50 countries.

Production Shift Manager

Responsibility for raising standards of safety, quality, availability, yield, housekeeping, people development and customer satisfaction.

· Researched, analysed and reduced process stops on the mini stacker outfeed of the manufacturing process by 70% with a cost saving of £200,000.

· Introduced, presented and demonstrated a system of incident inquiry that dramatically raised the level of trust between shop floor and management.

· Pioneered, expanded and introduced a housekeeping process that has delivered a professional looking and operator owned production area.

· Conceived, developed and established a quality education system that has enhanced the operator knowledge and reduced defect levels.

· Researched, negotiated and implemented a system of cover for absenteeism at a saving to the company of £88,000 based on year 2006 costs.

Kodak Limited, Annesley, NottinghamshireMay 1988 to Feb 2005

World leader in Imaging technology products and services to the photographic and graphic communications markets.

Engineering Maintenance Manager (Feb 2003 to Feb 2005)

Primary responsibility to develop the relationship between operations and engineering departments. Streamlining the maintenance programs and development of the engineering teams.

· Coached, demonstrated and utilised six sigma tools and techniques to increase productivity by 11%

· Organised, shaped and redesigned the engineering workshop to allow easier retrieval of tools and equipment.

· Restructured, encouraged, and motivated engineering teams resulting in reduction in mean time to repair across the whole site.

· Evaluated, reorganised and streamlined the engineering maintenance activity resulting in a 10% increase in production capacity.

· Negotiated, organised and provided nationally recognised multi-skill training packages resulting in quicker breakdown analysis and increased equipment uptime.

· Determined, communicated and established visual management method of engineering maintenance requirements resulting in accurate machine outage planning by and for the operational teams.

Operations Shift Manager (June 2001 to Feb 2003)

Responsibility for customer service and the integration and education of lean manufacturing tools and techniques.

· Assembled, organised and established a lean manufacturing based single piece flow line which reduced "work in progress" inventory by 78%.

· Organised, facilitated and presented solutions to problems that provided clarity, direction and implementation plans for project teams.

· Conceived, developed and introduced a quality review system which increased process knowledge and provided an understanding of failure modes with a resultant decrease in defect quantities.

· Restructured, presented and managed a visual production review system that reduced the required managerial time by 50%.

· Managed, coached and guided a multinational team to develop a lean manufacturing environment resulting in quicker changeover times and a 7% increase in customer service levels.

· Analysed, reduced or eliminated non value adding activities resulting in a reduction in factory throughput time of 70%.

Operations Team Leader (Nov 1996 to June 2001)

Management of small shift teams with the focus on internal customer supply and quality combined with first level conflict and absence management.

· Planned, facilitated and launched a new product manufacturing cell with a reduction in WIP of 96%.

· Investigated, designed and introduced poke yoke method of eliminating opportunity for error with a cost benefit of £90,000.

· Researched, remodelled and launched a fully empowered production cell with ownership for items of the value stream that became the benchmark for future cell working.

· Investigated, analysed and eliminated non value adding activities resulting in an 18% capacity increase on the line and negating the need to purchase additional equipment.

Shift Engineer (May 1988 to Nov 1996)

Reactive and planned preventative maintenance for a variety of metal forming power presses and injection moulding machinery. PLC programming and technical support.

· Planned, prepared and installed an overheat protection system to sixteen injection moulding machines that reduced stoppages and increased overall capacity by 2%

· Evaluated, compiled and delivered a PLC training package resulting in all site engineers being able to carry out basic system interrogation which decreased overall repair times.

Rolls Royce Limited April 1987 to May 1988

Rolls-Royce, a world-leading provider of power systems and services for use on land, at sea and in the air, operates in four global markets - civil aerospace, defence aerospace, marine and energy. Annual sales total £7.4 billion.

Instrumentation and Control Engineer April 1987 to May 1988

Preparation and calibration of test equipment for the examination of aero engine performance. Design and installation of specialist test rigs.

· Designed, fashioned and installed a test rig for monitoring temperatures at specific points on an aircraft wing that provided data for the successful elimination of a customer concern for the risk of overheat

· Examined, remodelled and resolved technical problems linking Grumman thrust reverser to a Rolls Royce Tay engine that helped to secure orders and develop the business.

Courtaulds Acetate Limited Aug 1978 to April 1987

Courtaulds Acetate, a business of Celanese Corporation, manufactures cellulose acetate products used in filtering and other industrial applications. Manufacturing facilities and sales offices in the United States, Europe, Canada, Mexico and Asia.

Instrumentation and Control Engineer (Aug 1982 to April 1987)

Installation, maintenance and fault finding on various equipment and processes relating to the chemical industry.

· Installed, commissioned and maintained a system for the re-use of acetic acid allowing waste to be treated and costs to the company to be reduced.

· Trained, guided and developed an engineering apprentice into a fully qualified time served engineer who was capable of working safely and efficiently.

Engineering Apprentice (Aug 1978 to Aug 1982)

Absorb, understand and utilise basic and core engineering skills before graduating as a certified engineer.

· Studied, learnt and absorbed knowledge and technical skills required to graduate with a fully indentured apprenticeship in Instrumentation and Control and a Higher National Diploma in Electrical and Electronic engineering.

· Absorbed, understood and developed the skills required to graduate from the engineering training school with total awareness of engineering machine shop safety and theory.

QUALIFICATIONS

Certificate in Business Management, West Notts College 2004

National Examination Board for Supervisory Management, University of Westminster 1995

Certified Instrumentation and Control Engineer, Courtaulds Acetate 1982

HND in Electrical and Electronic Engineering, Derby College of Higher Education 1979 - 1982

ONC in Electrical and Electronic Engineering, Derby College of Further Education 1978 - 1979

5 'O' Levels, Heanor Gate Science College 1973 - 1978

PROFESSIONAL TRAINING / QUALIFICATIONS

Lean Manufacturing techniques including 5S, Jidoka, Kaizen, Kanban, Standard Work etc

TPM - RCM - FMEA

Facilitation and presentation skills

6 Sigma Black Belt trained

Quality systems and targets

"Safetrack" Safety auditing

IT skills (Excel, Powerpoint, Word)

Autonomous Maintenance Practitioner

Team building and Outward bound courses