Lean Coach/Consultant

Lean Process Manager and Senior Manufacturing Manager with experience working in various industries with the ability to influence and implement change in fast pace, large volume manufacturing environments.

From May 2014 working as a self-employed Lean Coach across various contracts.

Open to opportunities in permanent or consulting roles.

Key Career Accomplishments

Reduced quality errors by 56%, resulting in cost avoidance of almost a half million dollars.

Introduced Kanban (Lean manufacturing) system for consumable items, reducing site expenditure by $600,000.

Consolidated three stores into main logistics center, resulting in a savings of $1.6 million.

Successful reduced staff from 43 to 13 operators.

Using ‘Pull Just in Time’ systems, reduced line-side inventory by a one-time savings of $670,000.

Introduced a standardized approach to material flow, reducing late penalty for deliveries from $300,000 to 0.

Synchronized site deliveries to OEM, reducing delivery frequency by 35 deliveries per week.

Reduced absenteeism from 9% to 3.8%.

Saved $112,000 through identifying continuous improvement opportunities and increasing productivity on processes, introducing multi-skilling, resulting in the removal of night shift.

Reduced lead-time from more than 8 hours to less than an hour while maintaining 100% customer service.

Reduced store inventory by 40% by evaluating non-moving items.

Employment History

Berendsen PLC November 2016 – February 2017

Lean Consultant London, UK

Implemented daily production meetings to capture SQCDM.

Trained management in OEE and implemented across 3 industrial laundry facilities.

Completed process mapping to identify bottleneck process, improved output and achieve OTIF to customer.

Processed standardization and documentation.

Conducted 5S training and implementation.

Network Rail April 2016 – November 2016

Lean Coach London, UK

Trained champions and team members in Lean tools and techniques.

Coached and mentored champions in project identification and implementation.

Lean Coach November 2015 – April 2016

Utilities, National Grid London, UK

Supported sustainment of National Grid Performance Excellence.

Coached and mentored in the use of Lean tools and techniques.

Unipart Expert Practices May 2014 – November 2015 Lean Coach for Utilities, National Grid London, UK

Coached and mentored three National Grid practitioners in the implementation of tools and techniques to create the National Grid Way, based on the Unipart Way and the Toyota Production System.

Shared best practice and experiences in culture change from Lean implementation across various sectors.

Associate Senior Practitioner for Royal Cornwall Hospital Trust

Identification and implementation of process, productivity and work flow improvements in Sterile Services department.

Waste elimination through application of Lean techniques.

Associate Senior Practitioner for Government Aerospace

Worked on a 62 million dollar UK Government funded scheme (Sharing in Growth) to improve the capacity and ability to secure worldwide orders of 40 UK-based aerospace suppliers by a minimum of 20%.

Lean Coaching Limited May 2012 – May 2014

Lean Coach London, UK

Provided services for a variety of clients, including Izhtrading (supermarket chain located in Russia), Daimler in Portland, Oregon, and Novo Nordisk (pharmaceutical company located in Denmark.)

Trained and coached clients in Lean methods across all business sectors.

DHL Supply Chain at Jaguar Land Rover May 2011 – May 2012

Senior Operations Manager Liverpool, UK

Managed 300 employees, including all areas of performance management.

Responsible for receiving, sequencing and delivery of parts to JLR production line.

Customer liaison with JLR senior management.

Identification of process improvements and cost savings.

Alstom Transport December 2010 – May 2011

Interim Manager Manchester, UK

Managed the supply of materials for both planned and reactive maintenance of up to 40 trains per night.

Controlled despatch of repair components to ensure stock levels of critical parts maintained.

In charge of calibrated tooling to ensure required tooling is available for operations and recalibrated as required.

Maintained safety and 5S standards.

Cert Octavian Premium Product Logistics June 2009 – November 2010

Continuous Improvement Manager London, UK

Responsible for implementation and roll-out of Lean methodology and tools at nine separate sites.

Worked with board and executive management team to identify focus areas of the business for Lean implementation.

Identified cost-saving opportunities in the business and developed implementation plans with general managers.

Collaborated with board and business development team to identify and remove waste from bid/tender process and reduce completion time.

Introduced versatility/training matrix to identify skills gaps and improve flexibility of workforce.

Conducted Value Stream Analysis and future state Blue Sky.

Provided monthly feedback to board and executive team on achievements and future projects.

Implemented standardized work, process standardization, process improvement and conducted 5S training.

Implemented practical problem solving training and mentoring to identify root cause of quality defects and implementing countermeasures.

Controlled waste elimination through application of Lean techniques.

MacFab Systems Ltd. March 2009 – May 2009

Lean Consultant Monaghan, Ireland

Implemented Lean practices: Standardization, Visualization, 5S, Process Improvement, Andon, Cost Reduction, Lean Layout, Kanban, Single Piece Flow.

Worked with shop floor influencers to create a Lean culture.

BVT Ship Building September 2008 – March 2009

Lean Consultant Portsmouth, UK

Implemented Lean practices: Standardization, Visualization, 5S, Process Improvement, Andon, Cost Reduction, Lean Layout, Kanban, Single Piece Flow.

Worked with shop floor to identify and implement improvement opportunities.

Bombardier Transportation May 2007 – August 2008

Lean Specialist Crewe, UK

Responsible for the training and development of operations managers, shift leaders and team leaders in all aspects of Lean manufacturing, Lean logistics and material control.

Supported methods team on improving standardized work documentation.

Introduced Lean manufacturing into an initial application area and subsequently, site-wide.

Mentored shift leaders and team leaders in Lean manufacturing techniques.

Introduced Kanban system for movement of materials from logistics center to production, creating Just-in-Time supply of material, reducing inventory line-side and creating single piece flow.

Designed and developed parts storage methods using Lean visual factory control tools to reduce operator-wasted travel.

TDS Automotive Logistics December 2005 – May 2007

Manufacturing Manager/Lean Specialist Liverpool, UK

Re-introduced Kanban system for JIT sequenced parts delivery across three shifts.

Introduced visual management of stock to prevent mispicking of components and aid inventory control.

Additional Qualifications

HNC Business Management

NEBOSH Certificate

British Army - Royal Engineers

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