Continuous Improvement Part-Time

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Boris Tapah, MEng, PhD, CEng, MIChemE

Peterborough, UK

Email: **********@*****.*** or Cell: +44-742*-***-*** SYNOPSIS

I am a dynamic Chartered Engineer with 10+ years of expertise in Engineering, Manufacturing, and Low Carbon Technologies. Known for my strong technical acumen, commitment to sustainability and innovation, I excel in planning and executing complex projects, enhancing operational efficiency, and achieving organizational goals. My proficiency in design assessment, compliance and continuous improvement ensures industry-standard excellence, making me an asset for driving engineering success. Key Skills and Expertise:

Project Management

Engineering Design - DFA

Manufacturing Engineering/APQP

Innovative & Sustainability

Chemical Engineering

Quality Control and Compliance

Research & Development

Gasification & Supercritical Water

Scale-up and System Integration

Continuous Improvement (Six Sigma, LEAN)

Hazard Analysis and Risk Assessment

Leadership and Bilingual Communication

Strong problem-solving skills

Collaboration Tools: Jira, MS Teams

Agile Methodologies: LEAN, Kanban, Scrum

Critical Thinking and Data Analysis

WORK EXPERIENCE

Career break (due to family personal issues) April 2024 to current Technology Demonstration Manager June 2022 – March 2024 Kew Technology – Sustainable Energy Centre, UK

Description: The focus was to oversee the planning, development, and execution of technology demonstration projects on Energy from waste. The main goal is to showcase the feasibility and potential of new technologies or innovative solutions.

Responsibilities:

Planning and coordinating relevant projects including setting project goals and timelines, developing project budgets, and identifying necessary resources and personnel.

Collaborate with R&D and engineering teams to design, implement, and optimize demonstration systems for converting organic waste into energy (syngas, H2).

Monitoring the performance of the selected technology systems to drive optimization for maximum efficiency, reliability, and safety.

Provide technical expertise and guidance on biomass gasification processes and technologies including assessing the technical feasibility, scalability, and business case.

Ensure all demonstration activities comply with relevant safety, environmental, and regulatory requirements.

Work closely with internal teams (R&D, engineering, operations) and external partners

(suppliers, research institutions) to ensure project success Manufacturing Research & Technology Development (MRTD) May 2020 – May 2022 Jaguar Land Rover – Automotive Manufacturing, UK

Description: I joined the newly set up MRTD function where I played a key role in introducing new technologies to foster innovation and continuous improvement in the manufacturing process. Responsibilities:

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Conducting research and development on new manufacturing processes, technologies, and materials to improve automotive manufacturing’s KPI (efficiency, quality, cost, and safety).

Developing technology roadmaps for the manufacturing process, which includes identifying opportunities to improve process performance, quality, cost, and productivity.

Leading cross-functional teams to manage projects related to new product launches, manufacturing process improvements, and technology implementations. Key Achievements:

Successfully implemented new technologies of autonomous paint defects detection and repair that resulted in millions of pounds saved of ROI.

Applied LEAN & Sig Sigma principles to implement continuous improvement initiatives (i.e. Benchmarking, Reduced variability, Gap analysis, Reduced cycle time), resulting in quality improvement and cost reduction.

Senior Manufacturing Process Engineer June 2018 – Apr 2020 Jaguar Land Rover – Automotive Manufacturing, UK.

Description: Applying manufacturing system validation principles to enable a smooth NPI/NPD in line with the company roadmap.

Responsibilities:

Represent manufacturing for all safety systems, Advanced Driving Assistance, Exterior trims, body lids, body doors, body structure, Glazing & roofs, and Accessories.

Responsible for the chassis contents as SME for Steering Wheel & Tyres.

Subject Matter Expert (SME) for Exhaust and fuel systems on all platforms.

Ensure all standardization approaches are defined and implemented to ensure a common manufacturing approach on all platforms including generating generic PFMEAs, control plans (CP), generic GSPAS, Bill off Process (BOP), and Bill of Sequence (BOS).

Conduct Design Verification activities to ensure cost-effective manufacturing feasibility.

Define & review process to ensure feasibility, optimal BMV, tooling, and fixture requirements.

Define and develop a Bill of Process and build the commodity library. Key Achievements:

Conducted design review activities to develop fully costed proposals for authorization.

Led the coordination of the Lessons Learned activities, I slashed Thing Go Wrong (TGW) issues management to closure by 45% in 3 months with a positive impact on process improvement.

Applied LEAN Manufacturing Principles to implement various continuous improvement initiatives

(i.e. Benchmarking, BMV reduction, YS-YC, and Lesson Learned management).

Developed comprehensive files to enhance manufacturing assessment study.

Trained new engineers on manufacturing impact and feasibility assessment studies.

Collaborated with the product development team to ensure all products complied with the BOP. Manufacturing Process Engineer - T&F Process June 2015 – May 2018 Jaguar Land Rover – Automotive Manufacturing, UK

Description: I joined the business as a manufacturing process engineer and was given the responsibility of managing the NPI / NPD – interior trim and fuel system components in the new model year. Responsibilities:

Manage the development and introduction of new and modified processes associated with new model introductions and model year changes.

Represent manufacturing and interior trim commodities in all relevant meetings.

Identify, raise, and manage technical issues to closure using AIMS.

Support the relevant virtual build events and manage issues where appropriate.

Assess design for DFA to suit manufacturing build requirements using Teamcenter and Catia V5

Ensure completion of PFMEA, Risk/complexity filter, GSPAS, Cost deck, and waste matrix.

Ensure the application of Lean Manufacturing and Design principles. Key Achievements:

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Applied LEAN to implement continuous improvement initiatives (i.e. Benchmarking, Health & Safety management, BMV reduction, Poke-Yoke, Special & critical characteristics).

Reducing Cycle Time in the Assembly Line through new fixing introduction, BMV, and NVA reduction.

Led the development of a set of worksheets applicable to the office and all plants for Health & Safety risk management.

Led the safety review through risk assessment of the office and plants.

Successfully validated product integration and processes through virtual and physical build events. Research Associate on Carbon Capture & Storage (CCS). Nov 2014 -May 2015 Heriot-Watt University, Edinburgh, UK.

Description: I was contracted to lead a project on Carbon Capture and Storage technologies. Carbon dioxide captured from large point sources such as power stations, transported by either pipeline or ship and stored safely / permanently in geological sources (e.g., seawater reservoir) is an alternative route for preventing CO2 from entering the atmosphere and contributing to mitigating climate change due to Green House Gases (GHGs). The issue is what happens if the CO2 leaks under its storage seawater reservoir. Can leak CO2 flowing under seawater be identified/ detected and quantified accurately? How much will this influence marine species? Do the scientists have validated models to predict CO2 hydrodynamic behaviour in seawater with and without sediment?

Responsibilities:

To lead the design of the experiments and set up equipment and techniques at Heriot-Watt University to answer some of these questions.

To lead the build, test, and ensure the safe operation of the pilot unit for CCS. Conducting a risk assessment, COSHH, managing project budget for £500K.

Implement, troubleshoot, and optimize acoustic techniques (ABS, sonar) to monitor the hydrodynamic of CO2 flows in the multiphase system and provide CO2 characterization data to validate mathematical models.

Key Achievements

Completed the project on time and within budget constraints.

Implemented a novel technique - the use of an Acoustic Bubble spectrometer for CO2 bubble characterization in real-time.

Collaborated and networked with industries and project stakeholders on CCS techniques. Research & Development Process Engineer Nov 2013- Oct 2014 Omega Proteins Ltd part of Leo Group, Cumbria, UK

Description: I joined the business as R&D Process Engineer in the foods rendering and oil processing industry to lead the management of NPI / NPD, project improvement opportunities, reduce manufacturing process costs, and improve on product quality. Responsibilities:

Leading the evaluation and improvement of the manufacturing processes and products - reporting findings and implementing optimization exercises.

Providing technical support to the production and quality teams; e.g. HACCP, ensuring product analysis conforms to ISO, review procedures, and supporting the implementation of NPI.

Leading the laboratory and/or pilot experiments, performing analyses, and gathering data for NPI

Leading the research and development of cost-effective methods for high-yield conversion of oil/fat into biodiesel, Assessing methods to add value to the plant waste.

Providing training to the process operator and analytical team on sampling & analytical issues

Generated and analysed various experimental details and presented them to the board of management.

Key Achievements:

Successfully led the commissioning of the newly built Anaerobic Digestion system.

Led the development of a new procedure for polyethylene analysis in oils (£300K saved + time).

Applied LEAN principles to enhance boiler performance: +8% thermal efficiency. 4

Applied Six Sigma principles to implement Continuous Improvement initiatives such as optimal oil refining conditions, impurities removal system, catalyst integration, and feedstocks analysis; resulting in a 12% increase in efficiency and quality for an estimated annum saving of £800K. Doctoral Researcher on waste conversion into energy and bio-fuels Sept 2009 – Sept 2013 University of Birmingham, UK

Description: There are many routes for producing bio-fuels (Hydrogen, Syngas) from wastes. However, the high-cost application constitutes a barrier to the commercialization of certain processes such as SCWG. The low-cost-effective technique is deemed necessary to enhance the viability of this route on a commercial scale. (Sponsored by the Engineering and Physical Sciences Research Council (EPSRC)) Responsibilities:

Lead the design of processes and equipment for high temperatures and pressures hydrothermal applications. Also, to lead the pilot unit construction and commissioning.

Process design activities include design calculations, sizing process equipment (PFR, separator column), drawing PFD, and flowsheet/P&ID using progeCAD /AutoCAD.

Conduct process description for the process in normal operating and shutdown procedures, and emergency procedures.

Ensure design data and pilot plant operations comply with BS, LEAN manufacturing, University procedures, and regulations.

Ensure safe process operations, completion of risk assessments, LOPA, and chemical hazards.

Lead the planning of the analytical experiments- for reactants, products, and catalyst characterization.

Key Achievements

Successfully led the planning, and execution of a project on time within the budget of £1.1m

Led the innovation and implementation of a new technique for low-cost organic waste gasification.

Implemented a new approach for converting a plug flow reactor into a packed bed reactor without compromising on reactor performance at high temperature and pressure application.

Applied Six Sigma principles to establish optimal reaction conditions, two stages of Gas-liquid separation, heat recovery system, catalyst integration, feedstocks analysis, and modeling.

Generated documentation such as a permit to work for the pilot unit, writing a report, thesis, and scientific articles published through the prestigious Renewables Journals.

Developed proficiency in the use of various analytical equipment including GC-TCD/FID for gas and liquid products analysis. Catalyst characterizations (TGA, ESEM, XRD, BET, Chemisorption). Process Engineer Assistant- Manufacturing of TAED July 2006 – Aug 2007 Warwick International, Chester, UK.

Description: I was contracted for 12 months to provide support to the process and design engineering teams for the specialty Chemical manufacturing of TAED. Responsibilities:

Supporting the identification and troubleshooting of manufacturing process issues

Designing (sizing, costing) and implementing a storage tank and platform

Writing process descriptions for the distillation, reaction, crystallization, and drying of plants

Lead the commissioning of the newly built sodium acetate plant

Managing projects for increasing boiler efficiency and reducing emissions on the absorber

Producing new P&IDs and updating existing ones using design tools such as AutoCAD Key Achievements:

Conducted Equipment Sizing, Specification, and Detailed Process Engineering

Updated or created design base layer documentation - PFD and P&ID using AutoCAD

Applied LEAN to reduce gas emission on the absorber by an average of 6 %.

Developed process description of the reactor and distillation units at the industry standard.

Led a team to successfully commission of the newly built plant for sodium acetate production

Led the implementation of the HAZOP study actions and associated tasks. 5

EDUCATION

Ph.D. in Chemical Engineering, University of Birmingham, UK. Sept 09- Sept 13 Project: Wastes conversion into chemicals and energy /Biofuels (Hydrogen, Syngas).

Implemented a low-cost processing of organic wastes by hydrothermal gasification.

Designed (P&ID, sizing, equipment specification), constructed, commissioned, and ensured a safe operation of the lab and pilot plant –scales for high-pressure hydrothermal gasification of organic wastes into energy and chemicals. The project was completed on time and within budget. Other postgraduates are now using the pilot unit.

Evaluated the Catalysis & Chemical Reactions in the hydrothermal conversion of Biomass.

Established optimal conditions for low-cost conversion of organic wastes into H2-rich gases, syngas, and valuable liquids products (alcohols and aldehydes).

Writing research reports, thesis, and scientific articles publication to renewable energy journals. Master Engineering in Chemical Engineering, Aston University, UK. Oct 2004 -July 2009

Final year, first class completion of a research project that included laboratory work and reports on the use of contact lenses for controlled ocular drug delivery.

In the third year, completed six months of research studies, where I produced one of the best designs (process and equipment) for the manufacturing of a drug (Penicillin). Studies undertaken include Mass and Energy Balance, P&ID using CAD, Process Description, Plant Layout, HAZOP, the design of the extraction column, and Materials Specification.

Achieved the highest overall grade (3rd year, Chem. Eng.) Engineering and Science Foundation (First class), Aston University, UK. Oct 2003- June 2004

First-class completed modules such as mechanical engineering, mathematics for engineers, Fundamental Physics, Chemistry and Materials, and Information technology.

Achieved the second-highest overall grade (76%). PUBLICATIONS

Tapah, B., Santos, R.C.D., Leeke, G.A., Processing of Glycerol under Sub and Supercritical Water Conditions, Renewable Energy, 2014, 62, 353-361. http://dx.doi.org/10.1016/j.renene.2013.07.027

Liquid products from glycerol processing by catalytic supercritical water gasification, Biomass Conversion, and Biorefinery, in press 2015

CONFERENCES & COMMUNICATIONS

Virtual build presentations as part of my role (Jaguar Land Rover, Gaydon), UK. Sept 2015 -2021 Guess speaker to post-graduate students at the University of Birmingham, UK. Feb 2018-2020 Presenting on gasification – 11th European Gasification (Gasi11) at Cagliari, Italy. July 2011 Presenting on Pyrolysis and gasification - international conferences on bioenergy (BIOTEN), UK. Sept 2010 ASSOCIATION & INTERESTS

Chartered Member (CEng), Registered member of the Engineering Council -UK, Member of the diversity

& inclusiveness Team at Jaguar Land Rover – Jan 2020 Volunteer (St Jude Church, Commonwealth game 2022), enjoys traveling, sports, and socializing. REFERENCES Available upon request.

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