Factory/Production Manager with 30 years hands on experience.

David Ian Booth

*, *******’s Court, **a Normandy Street, Alton, Hampshire GU34 1DE England.

014**-****** / 079**-******. *********@*******.***. **www.linkedin.com/in/mutterley**

CORE COMPETENCIES & SPHERES OF SPECIALISATION.

I have a 30 year career in Production/Manufacturing/Method Change across a wide range of varied projects, processes, materials and finished goods. This included (but was not limited to) Decorative and Vehicle Paints, Chemicals, Cosmetics, FMCG Food & Beverage, Cigarettes, Dairy, Mineral Water, Packaging (corrugated, blow and injection moulded) Household Aerosol Insecticides, Biscuits and basic Pharmaceuticals.

As a principled ‘hands on’ manager I work effectively from the ‘factory floor’ to ensure and encourage employee motivation, empowerment, acceptance of responsibility and succession planning.

I have a 6SIGMA BLACK BELT and qualifications in other ‘change methodologies’ including CI, LEAN, KPI’s & Kanban, MUDA, Kaizen, 5S, GEMBA, JIT, OEE & TPM/TPS/TQM. I have successfully implemented all such methodologies- my CV has specific numeric details of many examples.

I have lead project assessment, costing and subsequent equipment procurement and factory commissioning. Analysis of processes and costs of manufacturing.

I have a long standing practice that in order to maximise all components of the ‘manufacturing/production’ processes these areas need to be continuously monitored/amended in line with ‘defined’ P+L expectations and to enable identification and removal of non-added value costs & waste reduction across all areas (combined with the application of CI/Lean) from Directors/Senior Management downwards- all being essential components in the reduction of overheads which combined with ‘factory savings’ are directly aligned to the profitability of the business.

Autonomous responsibility for ‘stakeholder engagement’ at all levels. Acting as the ‘face’ of the business to suppliers, customers, the HSE, Local Authorities including emergency services if appropriate.

My experience shows that the ultimate ‘outcome’ of change/implementation/analysis in ‘simple’ form sets goals of OTIF 99.5% minimum, 0% equipment ‘downtime’, Right First Time 99.5% minimum, 0.5% returned ‘faulty’ goods and 0% reportable H&S incidents. Benefit is also achieved by creating a ‘happy working environment’.

I am a ’staunch’ advocate all HS&E requirements in any given manufacturing/production situation(s) from basic gloves to special PPE. I have NEBOSH & IOSH certificates which enable me to teach compliance with ISO14001 & OHSAS 18001.

I facilitate ‘identification, risk assessment & COSHH’ covering IMCO, COMAHH Storage Facilities, REACH, DSEAR, ATEX & GHS.

I established QC for raw materials & finished goods, accurate record keeping, identification & action to reduce/remove sub-standard materials before use, ‘quarantine’ where appropriate and coding & traceability for finished goods.

SUPPLY CHAIN –proficient and accredited in the use of SAP, ERP/MRP. Extensive experience in ‘sales based analysis’ to set up raw material purchasing systems aligned to Sales and Production Planning to ensure 0% ‘out of stock’ and ‘0% ‘overstock’. Monitor key raw material commodities

to be ‘ahead of the game’ in case of market shortages/price fluctuations.

March 2015 to September 2015.

MANUFACTURER OF LIQUID ‘HOUSEHOLD’ CONSUMABLES.

Appointed as Senior Production Manager to ‘manage’ from the factory floor 60+ employees involved in the production, filling and packaging of a wide variety of different products in varied pack sizes.

The business was in private ownership until mid-2014 when it was acquired by a larger Company operating from the North of England in a similar type of product range and client base.

The ‘takeover’ was not met with a positive response by the factory employees and this had created a very significant backlog of orders, failure to achieve more than a 60% order completion/delivery which had a ‘knock on’ effect with customers being unable to support their own client base with product.

I established very quickly that despite having 100+ active accounts, 2 prime clients accounted for >50% of the £4M p.a turnover.

An initial assessment of the ‘backlog’ showed that up to 90% of manufactured products were in an ‘out of stock’ position either by quantity available being less than on order or pack sizes available not being what was on order(s).

A recent stock check was also reviewed and missing materials ordered whilst the ‘principal’ raw materials (used in a high % of formulations) were put on a ‘regular’ order with suppliers.

After prioritising orders and combining ‘like’ formulations that covered multiple customers but with varied pack sizes/labels instructions to manufacture were issued. I spent considerable time on the factory floor monitoring activity to identify areas requiring urgent action by CI, waste reduction, improved process times and H&S. Where possible, ‘changes’ were implemented immediately. Factual ‘production planning’ was used to facilitate OTIF as the ‘norm’. Quality Control restructured to be effective at ‘problem pick up’.

The role is ongoing and I have established new procedures to improve the multiple areas requiring complete change. It will also take up to 2 months to catch up on ‘old orders’ ensuring new orders are assimilated with them. There also remain numerous ongoing problems including supply chain, H&S, environmental and risk assessment, fire control for hazardous raw materials and clarification/modification of existing MSDS to put them in line with newer legislation and other EU requirements on labelling.

March-September 2014.

DWC LIMITED. (March 2014- August 2014). MANUFACTURER OF ‘WAX’ CONSUMABLES/SPECIALITIES.

CONSULTANT to the Managing Director/Owner on 6 month contract.

Remit – carry out detailed ‘all area’ assessment of 2 sites – Productivity, Process, H&SE, QC/QA, Supply Chain, Production Planning, Employee empowerment, Hazchem/COMAHH, & ATEX Zoning.

Implementation of 6Sigma -Continuous Improvement/Lean Manufacturing. Output improved by 17%. Waste reduced to 1%.

Supply Chain modified to be ‘end to end’ and entered on SAP.

5S changes contributing to an 11% improvement on previous downtime.

OTIF improved from 66% to 97%. Direct positive impact upon increased profitability. Employee engagement and H&SE awareness improved in all areas. Stakeholder/customer satisfaction increased significantly.

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2010-2013.THE OPEN UNIVERSITY- MATURE STUDENT.

Bachelor of Laws (2:1) Degree LLB (OU)

Spent an unplanned 2 years in hospital for successful major reconstructive surgery on my spine after a motorbike crash. Dedicated time to complete a LAW DEGREE in the belief of its comprehensive benefits in MANUFACTURING - in areas ranging from Employee Grievance to complex Contract Negotiation within the Supply Chain function(s) - ‘terms of procurement’, ‘contracts of Sale for Finished Goods, ‘liabilities and terms of business’.

1998-2010. FUTURCHEM INDUSTRIES LIMITED.MANUFACTURER OF PATENTED ‘SAFE’ SOLVENTS.

General Manager/Co-owner. Prospect Works, Allerton Road, Bradford, England.

All products ‘formulated’ for specific applications in ‘SURFACE PREPARATION’ and to provide a range of ‘qualities’ and ‘solutions’ requested by end users in OEM AUTOMOTIVE & AEROSPACE. Crucially QC orientated therefore GMP enforced throughout. Considerable/service ‘tech support’ to end users.

Product testing carried out ‘on line’ at the customer’s facility in ‘real time’ terms. Manufacturing involved new equipment specifications, in house fabrication and innovative processes.

With positive results both parties signed a ‘secrecy agreement’ covering the ’technology’ after which orders commenced. CI, 5S, LEAN & 6SIGMA- implemented across all areas in support of rigid QC/QA.

By year 7, gross turnover reached £7M- gross margin remaining stable at 73%. Employed 60 F/T and 30 P/T.

A policy of working with the customer on Technical requirements generated an excellent ‘customer focused business’ with unique patented products that received multiple awards from the AUTOMOTIVE (MIRA) & METAL FINISHING Industries.

All products in a developing range represented unique & patented technology with efficacy and safety not available in any other products. As a result of these’ advantages’ it was possible to develop and supply ‘commercial’ products including Graffiti Remover, Oil Spill Remover, Patio & Driveway Cleaner & General Purpose Cleaner Degreaser.

1992-1998. LONGULF TRADING. GLOBAL FMCG CONGLOMERATE. SHIEKH A.A.S ANAM. Prince Albert House, Kingsmill Terrace, St Johns Wood, London NW8.

Autonomous/Team role as Manufacturing and Production Manager/Consultant for all project development, equipment and raw materials. Project assessment & costing, procurement. On site for commissioning/start up and to ‘troubleshoot out’ problems. Implement relevant systems and procedures including Continuous Improvement, 5S, Lean Manufacturing, 6Sigma, Health & Safety, Environmental responsibilities and detailed system(s) for all aspects of Quality Control.

Door to door/end-end documentation and traceability systems implemented as standard across all areas of manufacturing starting with incoming materials. Many varied Manufacturing Business’s with a base in Yemen and new factories being built across the Middle East and the UK. Partnered my previous employers.

New FMCG NON FOOD FACTORY x 3. SOAPS in Powder, Solid and Liquid form. REVERSE OSMOSIS WATER TREATMENT PLANT PROVIDING >2M LITRES/MONTH.

New FMCG FOOD & BEVERAGE FACTORY x 3. Production of >50 product types including Breads-loaves/stick/flat, Cakes, Biscuits, Snacks, Chocolate bars (including KitKat, Mars, Snickers, Bounty and Milky Way). Carbonated/Non carbonated drinks including Coca-Cola, Ginger Beer, Non Alcoholic ‘Beer’, Fruit Juices & Flavoured Fruit Drinks, Mineral Water & Dairy (see below).

NEW BEVERAGE FACTORY. Tea Bagging from Leaf (Liptons License). Coffee from Beans. Nuts & Dried Fruit Snacks.

NEW FMCG DAIRY FACTORY- UHT Milk, Baby Milk Powders, Favoured Milk Drinks, Yoghurt, Ready Made Custard, Jellies and other Dairy related consumer goods.

NEW FMCG CIGARETTE FACTORY. International brands under License and local brands. Manufactured from Tobacco Leaf and included in house printing of papers, inners and outer boxes. State of the Art facility. Full automated including all packaging/palletising. Tobacco warehouse included new technology ‘anti tobacco leaf bug infestation’ by computer operated air spraying ‘insecticide/pesticide’. Production of >1M cartons/month with expansion into local export markets (North Africa, Somalia, Eritrea).

NEW PHARMACEUTICAL FACTORY. Paracetamol & Aspirin B.P manufactured from powders. Syrups, Decongestants & Pastilles. Applied GMP, BRC/FDA guidelines. Planned introduction of Vaccines and other specialist medicines.

SUPPLY CHAIN-Cradle to Grave set up from existing information. After 12 months started end-to-end SAP (MRP/ERP) computerised system. Utilised the huge benefit of ‘group purchasing power’ to reduce material costs.

Start of year 2 - material cost savings of 17% equating to US$16.8M and a reduction in the number of suppliers by 21%.

CI, LEAN, 5S, KPI – introduced into chilled, semi chilled & UHT milk factories. Improvements of between 7%-15% in output.

‘Hands on’ leadership/management with 500+ local employees.

NEW PACKAGING FACTORY-located as a ‘central hub’ on the site of the 11 ‘consumer goods’ factories –production for in house use. Included Tetrapak, Flowrap, Corrugated board/boxes/cartons, Printed Food Grade Foil, Injection and blow moulding of bottles to rigid containers/Lids. Encapsulation & Blister packaging for ‘pharmaceuticals. Tinplate conversion to ‘cans’.

NEW AEROSOL Plant for INSECT KILLER- Flying & Crawling, Fragrances & Body Sprays/Deodorants.-including WELCOME FOUNDATION License to manufacture. 350,000 x 750ml per month output.

2 years review - reduction in ‘GOODS RETURNED FAULTY’ due to improved QC down from 19% to 4%. 5S DOWNTIME reduced from 13% to 3.4%. GROSS MARGINS increased from 11% to 27%. Raw material savings of 4% equating to a US$13M p.a direct saving. Responsible for manufacturing/production budgets and improvement to profitability and extension of product ranges.

1982-1992. N.P.C.F. - ARAB REPUBLIC OF YEMEN. CONGLOMERATE. SHIEKH A.A.S SHEIBANI.

Appointed as MANUFACTURING, TECHNICAL & PURCHASING MANAGER with a remit to develop and expand the production facilities for ‘PAINT & CHEMICALS’ enabling capacity and processes for the introduction of new products. New title – ‘FACTORY MANAGER’. 300+ local employees.

Remit commenced with the preparation of a 5 year plan to enable ‘remit to reality’.

Introduction of a ‘SUPPLY CHAIN’ on a manual basis pending computerisation of the business. Start of CONTINUOUS IMPROVEMENT.

Example of new facility – local build of 500,000 Litres of Bulk Liquid Storage to enable raw material cost savings of US$4M p.a, and full automation of materials to production with pre set pumping system. Massive timesaving in batch production quantified by the end of year 2 as 35% - enabled ‘spare capacity’ to be taken up by the pre-planned introduction of a large new range of products – lead to an increase in PRODUCTION of 70%.

By early part of year 3 ACTUAL product types being manufactured and sold increased from 46 to >300 and >500 by the start of year 5.

Start of year 3 of plan- introduction of KPI’S and Kanban Cards. Engineering/Maintenance started on 5S. 6SIGMA - the lead planning mechanism. LEAN manufacturing and introduced successfully at the start of year 4. QC/QA and ‘traceability’ systems put in place. Quarantine introduced.

By the start of year 5 actual sales driven production increased from 246,000 litres (1983) to 2.2M litres (1988). Value of annual sales by year end of 1988 had increased by 985%.

SECOND remit to establish manufacturing in a new factory commenced in 1985 under general heading of ‘PERSONAL CARE & HYGIENE’ PRODUCTS. Production commenced successfully with various Cosmetics, Body Oils, Creams, Shampoos, Hair Colorants, Roll-on & pump action Deodorants, Depilatory Creams, Medicated Creams, Sun blocks, Perfumes & Fragrances.

Further products were manufactured ‘under license’ from globally recognisable market leaders. Factory under HACCP, GMP & BRC Regulations/Guidelines at all times.

THIRD remit in second new factory commenced in 1986 under heading of ‘Household Cleaners, Disinfectants and Clothes Whiteners/Stain removers. Identical process followed as above including GMP, with machinery and raw materials approved for immediate ordering.

Attended training courses to gain greater knowledge in various areas and specifically to ensure PPE was addressed to a standard relevant to the hazardous nature of chemicals being used. Production commenced successfully with Hard Surface Cleaners, Lavatory and Bathroom Cleaners. Acid Descalers and Whiteners, Anti Bacterial Floor cleaner. Bleach for Cleaning and Whitening of Cloth’s (large business sector across the Middle East). First year production/double shift c280, 000 litres p.a. Production increased to c420, 000 litres by end of 1988.

In 1988 Group formed ‘alliance’ with another local large scale ‘business’ and established multiple new FMCG state of the art factories located around a central packaging plant that produced ALL of the various types of packaging needed. Included printing. Full details as shown above under heading ‘LONGULF’.

EDUCATION & QUALIFICATIONS.

ALLERTON GRANGE SCHOOL LEEDS, W.YORKSHIRE. 1972 -1978.

‘O’Levels Chemistry (A), History (A), Geography (B), English Lang (A), Mathematics (B), Geology (B), Social Sciences (B), RE (B).

‘A’ Levels Chemistry (A), Geology (B), Geography (B).

KITSON COLLEGE OF TECHNOLOGY, LEEDS, W.YOKSHIRE. 1978-1981.

HND Mechanical Engineering. HND Organic Chemistry.

OTHER QUALIFICATIONS.

Law Degree – 2013 (2:1)

6Sigma Black Belt – 1999. Continuous Improvement & Lean Manufacturing Certificates & Annual Training Courses.

NEBOSH Certificate – 1992.

‘Toyotarism’ courses attended- TPM/TQM/TPS – 1998.

HACCP/ASEPTIC & CLEAN ROOM Certificate – 1985.

Institute of Directors (London) Middle East Representative & Correspondent. 1982-1997.

Paint Technology & Colour Pigments Certificate – 1980.

HOBBIES.

Off Road motor biking and On Road Sports Biking.

Fresh Water angling especially Carp & Pike.

Dog Walking in coastal & local river areas.

Open Sea Diving to PADI 3 – 100M.

NOTE: In October 2014- January 2015 I was in Florida, USA assisting my daughter with relocation as a result of a promotion with her existing US/Global employer.

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