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Production/Manufacturing/Operations Director

Production/Manufacturing/Operations Director

Work Experience

A proven leader of manufacturing, supply chain and distribution operations with the ability to ‘make things happen’ in both growth and turnaround situations.
A skilled deliverer of performance improvement utilising lean manufacturing and business process re-engineering to reduce cost and lead-time into time sensitive delivery markets.
Has strong people management, commercial and systems skills with wide experience of supply chain management and manufacturing in Japan, USA, Germany, Sweden, Finland, Poland, South Africa, Taiwan, China and India


INTERIM MANAGEMENT & CONSULTANCY
2004-05: -
· Harman/Becker Automotive Systems, Bridgend (7 months)
£50M 1st tier supplier to BMW, Mercedes, Land Rover, SAAB etc.
Managing restructuring of systems and operations to recover from impact of rapid growth. 350+ staff, 10 hybrid production lines (robotic & manual) & a vertically integrated operation including injection moulding and anodising. Increased productivity by 35%. Successfully involved in transition audit from QS9000 to TS1649
· Harman/Becker Automotive Systems, Bridgend (1 month)
Assigned to improve performance of Line managers through ‘one on one’ coaching.
· Thomas Lloyd (Mail Order) Ltd, Treorchy
“Big Picture & Future State” mapping as part of ‘Creating Lean Enterprise’ initiative
· David Wright Accountants, Bridgend
Detailed ‘Due Diligence’ on manufacturing, operational and Health & Safety functions for proposed purchase of an £11 million electronic gaming machine manufacturer.


CAREER HISTORY

Décor Frame plc., Bridgend 2002 - 2004
Manufacture and distribution of framed mirrors, pictures and photo frames
Sales: £10 million: Budget responsibility: £6 million: 100 employees.
Major customers: B&Q, Focus, Next (Mail Order)
Production Director
Responsible for all aspects of production management, site operations, distribution & service
Leadership & management of a multi-functional team of 100+ support staff
Monitoring operating budgets, cost planning, materials and profitability
Developed BOM, MRP & planning/scheduling systems establishing information integrity
Re-organised factory layout & improved material/business planning systems to handle growth
Reduced delivery lead-time from 22 days to 48 hours through introduction of process controls
Achieved 25% increase in sales per employee through introduction of systems and controls
Reduced labour turnover from 22% per month to less than 12% per annum.
Developed innovative packaging solution to reduce mail order delivery damages & claims
Outsourced nationwide distribution to 3rd party carrier & managed subsequent partnership
Manufacturing from CNC machines to convert raw materials for final assembly

Steinhoff Furniture (UK) Ltd., Tewkesbury 2000 - 2002
Import, assembly and distribution of furniture to major UK retailers
Multi-site operation.
Sales: £16 million: Budget responsibility: £10 million: 80 employees
Operations Director.
Responsible for all aspects of multi-site operational & general business management
Controlled upholstery manufacturing unit and import of knock-down dining/bedroom furniture
Ensured effective customer service & compliance with business-wide quality goals
Planned & introduced new buildings, processes & controls for assembly of cabinet furniture
Successfully developed manufacturing processes in UK, South Africa & Poland
Dramatically increased throughput from 2,000 pcs/week to 12,000 pcs/week
Championed improvements to supply-chain performance from Poland and South Africa
Supported business development, contracts & sales to major UK furniture retailers
Successfully established a costing model to create pricing policies for joint ventures
Co-ordinated systems engineering, production forecasting & operating budgets
Outsourced nationwide distribution to 3rd party carrier & managed subsequent partnership

Universal Furniture Industries (UK) Ltd., Aberdare 1995 - 2000
Import, assembly and distribution of furniture to major UK retailers
Sales: £12 million: Budget responsibility £8 million: 120 employees
Operations Director
Responsible for all aspects of operational control & business management activities
Controlled an import, assembly, repair/refurbishment & distribution facility for the UK
Reduced delivery lead-time from 4 months to 2 weeks through introduction of process controls
Utilised MRP, MRP2 & JIT techniques to improve business performance and efficiency
Re-layout of factory to improve process flow through cellular manufacturing concepts.
Successfully increased output per employee by over 148% through improved control
Outsourced nationwide distribution to 3rd party carrier & managed subsequent partnership
Established improved supply-chain processes between factories in China, Taiwan & UK
Improved Health & Safety procedures, reducing factory accidents by 67% over 18 months
Championed cultural change initiative to allow future business growth & profitability

Datamatic Ltd., Caerphilly 1989 - 1995
Manufacture of continuous computer stationery through capital-intensive processes.
Sales: £22 million: Budget responsibility: £15million: 230 employees:
Major Customers: Chase Manhattan Bank, Girobank, Tesco, W H Smith
Works Director
Responsible for all aspects of works management, engineering & operational control activities
Multi-shift, engineering based conversion of bespoke printed products & continuous stationery
Achieved accreditation to ISO 9002 through team building and continuous improvement.
Dramatically reduced inventory levels from £1.5M to £0.4M through process control initiatives
Successfully cut product delivery lead-times from 10 days to just 3 days
Key member of team that turned a £450K loss into a £1M nett profit over 3 years
Re-layout of factory: specification, purchase & installation of capital plant
Downsized from 230 to 80 employees and returned business to core activity and profitability
Increased sales per employee by 76% through re-structuring and continuous improvement
Re-engineered customer service procedures achieving a 150% gain in administrative efficiency
Managed ‘forms management’ operation for major bank, including ‘to desk’ delivery
Outsourced nationwide distribution to 3rd party carrier & managed subsequent partnership

Elac Ltd., Bridgend 1987 - 1989
Manufacture of loudspeakers for automotive industry, inc Ford, Rolls Royce, Rover
Multi-site, unionised operation
Sales: £10 million: Budget responsibility: £10 million 550 employees
Works Manager.
Responsible for all aspects of works management within a multi-site environment
Appointed to manage expansion of works facilities & production output levels
Led implementation of expansion into new facilities to increase output by over 40%
Controlled manufacture of loudspeaker products for automotive and professional markets
Complex mix of small batch & high volume requirements with significant changeover issues
Introduced and developed a comprehensive training programme enabling empowerment
Reduced on–line rejection from 13% to < 5% in 3 months by Kaizen/continuous improvement
Championed attainment of Ford Q101 quality award and approved supplier status


Sony (UK) Ltd., Bridgend. 1975 - 1987
Manufacturer of televisions and television components.
Senior Engineering Manager.
Responsible for all aspects of divisional production & engineering management activities
Gained significant promotion from technician to senior engineering manager encompassing responsibility for production, engineering and quality functions during growth from 250 to 1500 employees.
Developed and installed innovative production system generating 400% productivity gain
Conducted final build, trials, installation & commissioning of major CNC production system
Member of project team for £45 million expansion of television ‘tube’ plant
Led the company’s first outsourcing venture for assembled parts, writing relevant quality manuals, training and controlling the suppliers’ management and work force.
Founded and chaired company Quality Review and Improvement Programme that was ultimately key in Sony gaining the National Quality Award
Achieved set-up reduction from 2 days to 1 hour





PERSONAL & PROFESSIONAL DEVELOPMENT

World Class Manufacturing Concepts (Cranfield University 2002)
Currently studying Six Sigma
Post Graduate Diploma in Management Studies (DMS)
Management, Manufacturing and Quality Systems. (Japan)
Kepner Tregoe problem solving techniques
Trained in Method Study and Work Measurement
Radio & Television servicing (City & Guilds).

Date of birth: 12th January 1950. Status: Married


Education

World Class Manufacturing Concepts (Cranfield University 2002)
Currently studying Six Sigma
Post Graduate Diploma in Management Studies (DMS)
Management, Manufacturing and Quality Systems. (Japan)
Kepner Tregoe problem solving techniques
Trained in Method Study and Work Measurement
Radio & Television servicing (City & Guilds).


Skills

Lean manufacturing, continuous improvement, productivity improvement, cost reduction, factory re-organisation, mentoring & coaching

Languages

English

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