CV

Cost Reduction / Continuous Improvement Programmes

The cost reduction / continuous improvement programmes offered can be split into two main areas:
Initially I provide in-house training to the company's own employees. This provides the basis for an ongoing system which is both cost effective and is proven to give the best results overall.
The training programme is not a simple "text book" set of principles, it involves changes to mindsets and shows how to develop the skills of lateral thinking, open minded working, thinking beyond the square, problem solving techniques, etc.
Having established a different approach to problems, I then cover various proven techniques in effective cost reduction. This gives a structured approach to the various stages of the programme. The techniques used are well proven within many companies.
Following on from the training, I will establish a system which can effectively control and monitor all the cost reduction / improvement opportunities.

Lean Manufacturing Techniques

Review of current manufacturing plants and systems with reports on the areas where improvements can be made to lead towards a lean manufacturing system.
The major principles of lean manufacturing such as one piece flow, Kanban control procedures, PokeYoke error proofing, line balancing, tact time achievement, etc. are incorporated into the proposals.
The setting up of new manufacturing and assembly tracks to meet lean principles, including the identification and specification of suitable equipment, tooling and fixtures.

Project Management

Establish and manage specific short to medium term engineering projects. These include timing and cost plans, monitoring of projects from conception through to production and the management of research and development programmes.

Previous Projects Undertaken

• Design of a complete facility for the assembly of new vehicles. Included the specification, ordering and management control of all equipment, tooling and fixtures. The track was designed to give a lean manufacturing base against a fixed TAKT time.
• Cost reduction programmes with major automotive companies. These included both in-house cost saves and supplier material cost reduction programmes, DCD workshops, supplier events and teardown reviews.
• Cost reduction training programmes established and undertaken for a range of companies in both automotive and non automotive businesses.
• Multiple training sessions in problem solving techniques and team building programmes for a company which was seeking to improve its internal communications and product development / cost reduction programmes.
• Expert Witness reports on resource and timing planning and business systems.
• Long term contract with an overseas automotive company to update their designs and manufacturing techniques for 4 x 4 vehicle driveline and steering systems. Vehicle performance characteristics were assessed and advice given on vehicle test programmes. Advised on business / quality improvements to world class standards.
• Provision of design and engineering programmes within vehicle transmission systems for both UK and overseas companies. These included alternate component design options, improvement programmes to overcome manufacturing, quality & service problems, new design proposals and supplier evaluation & cost programmes.
• Designs of transmission test rigs for overseas vehicle manufacturers. Advised on the sourcing of suitable component parts. Negotiations carried out with UK suppliers on supply of complete rigs and parts. Business negotiations were set up between suppliers and client.
• Establishment of time and cost recovery plans for introduction of a new model for a UK specialist vehicle manufacturer. This included plans to meet both pre-production and production deadlines.
• Departmental resource planning covering timing plans and work load distribution for over 150 engineers.


Previous clients include: Azure Dynamics (Canada & USA); Bentley; Dae Dong (Korea); Jaguar; LTI; Land Rover; MG Rover, Mahindra Automotive (India); Mahindra Tractor (India); Metrocab; Modec; Tata Motors (UK & India); Widney Leisure.