Experience

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  Cummins inc.

  Jan 2009 - Jan 2019

  Senior manufacturing engineer

  •Led £5M transformation project on production lines creating a process & culture change to facilitate transition from “bay build” manufacturing units onto automated assembly lines•Managed plant setup & product transfer projects (engineering & assembly models, infrastructure layout & technology requirements) to compile pre-contract documentation•Directed initial design review, finance planning & lean assembly workshops to ensure successful alpha, beta to final launch builds for NPI projects onto existing production lines•Launched implementation of MES4.0 SDLC projects (DC tooling, Failsafe process, visual data systems) for build accuracy & traceability along with feedback loop to existing ERP system•Streamlined BOM structure & production routings, within operation ERP system to reduce line shortages stops & progress work through the factory in a robust & efficient manner•Authorized production documentation for new equipment & product- process flow architects, standard works, SOP, tooling spec, ergonomic worksheets, jigs and fixtures •Managed suppliers on site for Capex implementation stage ensuring installation operations are in line with RAMS, lift & logistic plans for NPI/4IR automation/ process improvement projects •Executed Capex infant care activities (initial site trials, audits, training & maintenance program) obtaining feedback on first production series to confirm manufacturing readiness •Managed an engineering team by actively practicing situational leadership behavior to utilize group dynamics against project requirements for effective task delegation & team performance•Developed resources through talent management system to ensure they can deliver responsibilities & have the prerequisite skills for a Continuous Improvement environment•Conducted appraisal reviews- reflecting past performances, providing constructive feedback, highlighting achievements & setting development plans with review targets for next period Show less

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  Caterpillar inc.

  Jan 2019 - Jan 2021

  Senior project manager- manufacturing

  •Led strategic Procurement, Quality, Lean projects with various stakeholders to improve assembly efficiencies & production output while driving £3M cost reduction in a labor-intensive environment•Detailed initial value model justification (business challenge vs vendor solutions, expected benefits, timescale & investment) into executive summary for stakeholder buy-in presentations •Directed vendor team through product-based work packages, progress & quality assurance, change & risk control at the end of each project milestone stage for execution within agreed contract metrics•Managed contractors on-site: setting weekly objectives, reviewing daily work schedule, monitoring performance, providing feedback on deliverables & driving safe H&S working practices•Analyzed critical production data (cycle time, inventory, labor/machine utilization) to conduct Kaizen workshops, optimizing line balance, work flow & factory layouts to meet customer demand•Developed & presented VSM proposals (current & future state) to functional teams, outlining initial PIDs & Briefs (scope, objectives & deliverable) through to detailed improvement & delivery plans.•Managed change request- analyze, assess impact, create communication channels, coordinate, review & sign-off change deliverables within timescales on people focused processes•Oversaw project risk management through a systematic process of identifying, assessing, planning & implementing responses •Optimized BOM & SAP production order routing against PLM to manufacture NPI, rework & spare components ensuring correct part, quantity, and operation structure in MRP system for job orders •Advanced compliance & audit readiness, facilitating internal & external audits to ensure adherence to ISO9001 & OHSAS standards, aligning with the Caterpillar & Safran quality assurance framework. Show less

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  Safran

  Jan 2019 - Jan 2020

  Principal manufacturing engineer (contract)

  Managing lean manufacturing strategies to increase production capability & capacity through the transition of batch build non-integrated process towards a smart connected production unit Compiling project PID’s (communication plan, risk profile, control procedure & schedule plans) to initiate & develop business mandate- automating production to achieve process excellenceImplementing CI Lean principles- 5S, Kanban, SMED, JIT/FIFO, 7W, effective workflow & layouts to reduce waste while improving RFT, efficiency & quality KPI’s Developing BOM’s to reduce stock discrepancies while maintaining control of ECR/MCO/QA, NPI & off-spec projects to ensure components are identified & production ready in a timely manner. Leading structured root cause analysis on production failures & quality issues using problem-solving tools i.e. FMEA, 5Y, 8D, PDCA, fish bone & TPM for corrective action & resolutions Facilitating VSM Gemba events to develop baseline capacity model (VA/NVA, Takt/cycle time, throughput/lead times, machine utilization) & A3 reports to remove bottlenecks & improve flowLiaising with vendors to build proposals- concept to contract award, tracking sub-project progress & monitoring specialist work package delivery to achieve Capex project objectivesCoordinating vendors & external teams for site-based equipment installation activities in line with approved HSE work statements for successful execution within agreed contract metricsManaging risk encountered through a systematic process of identifying, assessing, planning & implementing responses to effectively reduce & control uncertainty impacting project objectivesProducing project closure & highlight reports (safety records, end user documents, maintenance plan, stage summary & progress photographs) for senior stakeholder reviewsConsulting in Industry 4.0 digital discovery workshops & providing area expertise to outline roadmaps for an effective MES/Windchill implementation to robust production process Show less

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  Collins aerospace

  Jan 2020 - Jan 2022

  Engineering project manager (operations)

  •Achieved $2M M&A cost synergy target & advanced departmental KPIs in line with project portfolio & operational strategy to achieve BU mandate of 2x top line & 10x bottom line growth •Directed a multi-disciplined engineering team- fostering synergy among purchasing, projects, manufacturing & quality assurance, for execution on daily operations & mid/long-term business goals•Managed departments’ annual budgets- strategically allocating & governing spending, building necessary capability to ensure all project elements delivered as per agreed plans & customer schedule•Applied internal evaluation frameworks to determine project feasibility & financial realization to securing contract approvals & support for effective delivery in accordance with BU strategic plan•Led complex NPI product development cycles- managing from quotation to implementation, first article development, schedule coordination, build process sequence & seamless end-user handover•Advanced value stream optimization by leveraging MES & Industry 4.0 technologies•Managed Kaizen rapid response team- addressing supply challenges with agile solutions & process adjustments- plant layout/equipment/labor set up, part & material validation, non-standard builds•Facilitated change management (workshops, training system & methodologies) acting as a change agent to coach, guide & mobilize teams through adoption phases on people orientated projects •Conducted daily Gemba walk, ensuring production agenda is being adhered to, distribute & exchange technical information with cross functional units for decision making & corrective resolution•Governed teams rituals- setting weekly objectives & daily work schedule, facilitating start of shift meetings, team communications, sharing wins & best failure to reinforce a results-driven work culture•Maximized & developed team performance by implementing a structured approach to accelerate success behaviors Show less

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  Caljan

  Jan 2022 - now

  Service leader ireland (new business development- sales, project & operations)

  •Developing Caljan Ireland’s business strategy, collaborating closely with the UK CEO & Group level management/board, diversifying & scaling to achieve a multi-year P&L growth mandate.•Directing at operational level- leading resources to execute market expansion beyond core sectors, acquiring new clients effectively mitigating revenue risk•Leveraging market intelligence/economic forecasts to identify macro/micro trends in key segments/local culture/ways of working to establish Caljan as dominant leader in the Irish market.•Accountable for investment discussions with senior VPs/stakeholders, to obtain revenue recognition approvals by presenting financial models- projections/metrics (ROI/NPV) to guide decision making•Representing Caljan at expos/industry key events, building brand awareness & revenue prospects•Facilitiating bidding process to win key contracts, working with senior account managers overseeing contract development to secure major Irish accounts- DPD, DHL & FedEx among others.•Managing client relationships via meetings/site Gemba visits focused on a ‘farming’ consultancy approach for client’s business continuity plan (age obsolescence, disaster/crisis management)•Developed a systematic follow-up for field complaints- developing an action plan to comply with contract conformity, engaging with customer to change perception & ensure business retention•Supporting ISO9001 certification & compliance, conducting regulatory audits on internal & external service operations to establish a robust QMS to further customer retention & market share objectives•Developed regional supply chain capabilities- targeting local partners, negotiating procurement KPIs(Cost, Quality, Delivery) & overcoming cultural barriers to support business growth mandate•Creating a culture of high performing teams to achieve the strategic goal of market expansion Show less