Henry Hallak

Work as a consultant for the following Production Management, Operations Management, Total Quality Management, Project Management, Leadership: Management and Skills, Maintenance Management, Cost Risk Management, Manufacturing Strategies, Agility and Tactics, Manufacturing Engineering, Process Improvement, Business Process Re-engineering, Logistics Management, Change Management

Working as a project manufacturing engineer for the introduction of the new Cylinders manufacturing Cell. To carry the industries of the new cylinders manufacturing cell.
Zodiac Aerospace at Driessen Aircraft Interior Systems (THAILAND) LTD. Galleys & Equipment. 12/12/2011 to 10/03/12
Project Manufacturing Engineer Consultant (Logistics)
Working as a Change Agent, to reduce cost and increase operational efficiency.
Key responsibilities included; Coaching, process improvement and developing the process voice, introducing direct line feed and in-process measurement.

Parker Hannifin 4/10/11 to 28/10/11
Manufacturing Engineer Consultant (Lean continuous Improvement)
Engineer contractor base at Turkey to carry out initial study for the introduction of the new product on exiting production flow line.

Rolls-Royce MOD 09/10 to 07/11
Project Manufacturing Engineer Consultant
The Fans blade manufacturing process is made up a series of sub-processes each of which contribute to the generation of the finished part. Many different process types are used including hot forming, welding, finishing, machining, and inspection.
This project will investigate the process control and quality aspects of each process in detail and clearly identify the relationship between input variables and output at each stage of the process, ensuring that each process, and hence the component as a whole is manufactured right first time.
The team will apply a comprehensive suite of process control tools that exist within Rolls-Royce, including PFMEA, Control Plans and Characteristics Matrices amongst others.
Airbus Operations UK, Filton and Broughton (Aircraft manufacture)

Manufacturing Support Engineer Consultant (Lean continuous Improvement) 01/01 to 04/10

Working as a Change Agent, to reduce cost and increase operational efficiency.
Key responsibilities included;
• Ensuring supplier production series readiness including FAIR for A380 trailing edge.
• Delivering key raw materials logistics projects for the LCMA.
• Leading strategic process improvement projects.
Key successes included;
• Delivering concession reduction projects with a recurring annual return of £750k.
• Project leading the supply of a billet trailer with a total value of £1M.
• On-time delivery of A380 trailing edge package.
• Project managing the introduction of in process measurement for reducing setup time and manual inspection and the manning from 3 to 1 with a cost saving of £570K.

TRW Aeronautical Systems Ltd., Birmingham (Aerospace components) Manufacturing Engineer Consultant (Logistics) 01/00 to 12/00
Key responsibilities included;
• Introducing Direct Line Feed for manufacturing.
• Production layout improvements and associated training
• Trico-ethelyne cleaning project.
Key successes included;
• Improved component supply with annual cost saving £336k
• Delivered 5S (workplace organization) training for operators and improved layout of cell.
• Replacement of a Trico-ethelyne component cleaning system for machined parts

Management of moving manufacturing lines and flying parts with no stop to deliver to FAI. Involved close liaison and coordination with subcontractors carrying out capital project and M&E services.
Proposed solutions to new process/tool requirements for effective change management.
Red lined drawings &Technical File / review. Materials selection Manufacturing methods and technologies
General understanding of, Process Engineering Equipment selection and specification
Fuel control system Prismatic Centres of Excellence (cell 3)
Responsible for the design and layout of 3off cells of 4 & 5 axis CNC manufacturing machining cells. Managed quick change-over, tooling data transfer, SPC introduction, control of documentation and procedures.
Pri Prismatic Part Transfer Current and New Design
12 months mainly working in product transfer of Aerospace components from site to site. (Shaftmoor Lane, Fordhouses and Huyton to first article)
Managed a multifunctional team of design and manufacturing engineers; designing fixtures and tooling; CNC programmers and the proving of complex prismatic parts on 4 and 5 axis machining centers. To suit single piece flow lines. Fuel control system valves Centers of Excellence cells 1 to 3
Setting up manufacturing cells for jet engine actuator, valves & fuel pumps.
Designing fixtures of new methods and developing new manufacturing processes to implement new improved CNC plant layout for improved workflow to efficiency to Takt times.

Falcon Engineering Production Ltd., Birmingham (General engineering)
(Milling, Drilling, General Engineering, Swiss Auto Turned Parts, Capstan & Automatic Turned Parts and CNC Machining Centre)

06/99 to 01/00

Delta Electrical Ltd., Birmingham (Industrial and domestic electrical switchgear) 06/98 to 05/99
Project Engineer

Responsible to the Engineering Manager for the implementation of cost reduction projects
Key responsibilities included;
• Design and implementation of EXCEL based capacity planning for the manufacturing and assembly cells.
• Delivering key improvement projects.
Key successes included;
• Secured investment worth £50k from European funding body to deliver engineering training.
• Streamlined customer returns process to shorten cycle-time by 30%.

IMI Norgren LTD., Staffordshire (Industrial pneumatic valves) 04/96 to 05/98
Project Engineer

Responsible to the Manufacturing Engineering Manager for the implementation of new manufacturing systems within this highly automated CNC batch manufacturing environment
Key responsibility included
• Analysis of all key manufacturing processes and issuing of management reports to allow prioritisation of improvement activities.
Key success
• Implementation of in-process measurement and control procedures to increase process capability to Cpk 2.0 and reducing CNC machine set-up times from 120min to 2min realise annual savings of £0.5M per machine. Compilation & presentation of technical reports (in particular for 13th national conference of Advances in Manufacturing Technology at the Caledonian University, Glasgow)

Various including Midland Repetition Co. Ltd., Coventry and PBM Components Ltd., Birmingham (Furniture and automotive components)
9/95 to 03/96
Key success
• Commissioning and monitoring the performance of a four axis CNC machining centre and a DEA CNC Co-ordinate Measuring Machine (including programming of Siemens control software system)