Jun 2005 - Dec 2005

Production Manager

Vitafoam, Middleton, Polyurethane Foam Manufacture

Slabstock foam manufacture via a 'Hennecke' continuous processing line producing up to 600 Kg of slabstock foam per minute and a gross volume of 20,000 Te/PA.

Responsibilities

Sales Order Planning, Production, H&S, Quality, Stock Holding

KPI'S

(Key Performance Indicators)

Number of changeovers, unplanned stoppages, %scrap, in-process material losses, %substandard stock, value of stock inventory

Direct Reports

18 Unionised (T&G) - Team Leader, Process Chemist, 15 Process Operatives, operating double day shifts

Regulatory Compliance

COMAH 1999 , bulk storage & processing of isocyanates

Achievements:

• Established Hennecke Head set-up & start-up parameters, mixing head dip bar position, catchment start frame conveyor position
• Controlled commissioning & acceptance trials for Albrecht Baumer polyurethane rotary vertical cutting band knife, validated cutting length, block weight & print information parameters. Organised operator training, provision of training manuals & SOP
• Established protocol for marking grade changes, minimised cut-off scrap at the band knife - reduction in slabstock polyurethane process waste from 3.8% to 2.5% (annual saving of ~80K) through improved OEE initiatives

2001 - 2004

Manufacturing Manager

Coates Lorilleux, Rochdale - Printing Ink & Surface Coatings

Chemical storage, processing and filling operations of bulk surface printing coatings manufacturing capability for 15,000 Te/PA, both aqueous and solvent based dispersions of pigments & resins

Responsibilities

Budgetary, Batch Manufacturing, Preventative Maintenance, H&S, Lean Initiatives, Training & Developing

KPI'S

OTIF, batch cycle times, batch yields, kilo's per man hour, processing waste, value & number of rejections

Direct Reports

45 Unionised (GPMU) - 3 Production Controllers, 4 Supervisors, 38 Process Operatives, operating double day shifts

Engineering Contract Manager & 3 multi-skilled engineers

Regulatory Compliance

DSEAR 2002- storage & processing of ~100Te of solvents

Achievements:

• Improved delivery performance in a reactive industry sector through, leadership, KPI introduction, increased workforce flexibility, establishing capacity guidelines and de-bottlenecking. Improved OTIF from 83% to 95% over a 12month period for a product range >2000 SKU's
• Introduced lean manufacturing principles, including 5S tools - PPM Registers, Shadow Boards, Kaizen - PPM Schedules, out of hours automated milling (30% increase in OEE) , Kanban - supplier component replenishment system; to change work systems, ethics and cultures and establish bench marking for continuous improvement
• Controlled contractor civils, commissioning & acceptance trials for installation of 'News Ink', carbon black shear mixing & bead milling semi-automated plant
• First year reduction in overtime spend from 5% to 2% realising a labour saving of £21,000
• Reduced departmental absence from 9% to 5% (introduced Bradford Factor indices's)

1998-2000

Manufacturing Projects Manager

Cussons (UK), Salford - Personal Care, Aerosol & Household Products Manufacture

Chemical storage, mixing and blending surfactant systems under atmospheric and vacuum conditions using both continuous & discrete batch processing semi-automated plant, volumes manufactured in excess of 20,000 Te/PA

Responsibilities

Project management & local site technical support

Achievements:

• Championed the transfer and scale-up of all R&D 'New Product Development' projects from Pilot Plant/Test Room conception through to a local manufacturing capability
• Evaluated the dispersion of Carbopol (cross-linked polyacrylate) & guar powders with high shear (>5000 rpm) mixers & homogenisers
• Technically resolved processing issues associated with closed loop direct injection of iso-pentane into gel base prior to aerosol bag-on-valve canning (In-house manufacturing support of 'Foamburst' Shower Gel at Nottingham)
• Local project management of complete range of 'AquaSource' personal care range of toiletry products, both liquid blending & high speed filling (including change parts)

1993 - 1998

Technical Production Manager

Cussons (UK), Salford, Greater Manchester (as above)

(Process description as above)

Responsibilities

Budgetary, Production, H&S, Training & Developing

KPI'S

OTIF, batch yields, number of QA submissions, processing waste, number & value of rejections

Direct Reports

18 Unionised (T&G) - 2 Team Leaders, Fragrance Stock Controller, 15 Process Operatives, operating double day shifts

Regulatory Compliance

Electrical Equipment Regulations 1988 - solvent processing

Achievements:

• Introduced cost effective pigging systems (air driven silicone shuttles) to propel static pipeline finished product through to filling line heads - additional ~1% by volume realised as finished pack stock
• Managed decommissioning of talcum powder ethylene oxide sterilisation plant
• Controlled commissioning & acceptance trials for Guisti vacuum mixing vessel, validated in-line pH & viscosity meters to reduce batch cycle times
• Commissioned & later modified 5Te/Hr continuous metering pump & shear mixing process for dilution of Sodium Lauryl Ether Sulphate - cost saving of ~£20,000 PA
• Development of NVQ Level II Chemical Processing assessment package
• Six month secondment managing high speed filling line operation