Production Engineering Supervisor
Premier Composite Technologies
Total years of experience :15 years, 8 Months
Premier Composite Technologies, a leading global supplier and manufacturer of components for the aerospace, architectural, automotive and marine markets. Responsible for driving the continuous improvement across Safety, Quality, Cost, Delivery and People within the 24/7 CNC manufacturing departments. Recent projects managed include the $2.7m Dubai Apple Store ‘Solar Wings” and Maserati Alfieri concept components.
• Safety - created the H&S policy for the Manufacturing department. This included; risk assessments, department regulations and manufacturing protocols. Developed interlocking safety screens to create modular safe working zones. Implemented morning 5s audits and weekly toolbox talks to recognise and control hazards.
• Quality - successfully reduced part rejection rate from 7% to 1.4%. Using 6sigma techniques identified part rejection root causes; inadequate inspection process and machine calibration. Developed a ‘Work Categorisation’ system, designed to allocate specific resources depending on categorisation. Includes specific work processes covering quality control, required level of supervision and machine calibration procedures.
• Cost - reduced average monthly tooling expenditure as a result of supplier sourcing and negotiations from $14, 761 to $9, 873. Increased manufacturing profit on mass produced component by 12%, through automation and interchangeable fixtures to reduce set-up time.
• Delivery - originally 92%, now achieving the 100% on-time delivery target. Methods have included; creating a Production Preparation Process Team to review all parts prior to manufacturing and implementing daily progress meetings with team leaders.
• People - stronger focus on client liaison; regular progress reports and clear communication aid in building strong working relationships. Developed a comprehensive training programme, including work instructions for all manufacturing processes to upskill the team and achieve a flexible work force. Recognised capability and developed ‘specialists’ to oversee each section, providing support and guidance to the juniors. Created a screening process for future employees.
Universal Race Technologies, a leading manufacturer and engineering solutions provider for the aerospace, automotive and defence industries. Responsible for ensuring manufacturing deadlines were met and improving quality across the department. Projects have included Project Bloodhound (land speed record attempt), components for Aston Martins Le Mans Prototype and several Formula 1 projects.
• Line bottlenecked during part loading - Overall Equipment Effectiveness affected due to low performance. Using Single Minute Exchange of Die concept, designed and developed quick release-multipart fixtures. Result was a performance increase from 62.5% to 79%.
• Scheduling - allocated department resources to meet project requirements. Ensured manufacturing schedule was adhered to. Provided regular progress updates to relevant departments.
• Training - responsible for developing the manufacturing department. Focused on growing a highly skilled and adaptable team to improve quality and cover unexpected leave.
• Mould Making - variety of complex moulds predominantly for the automotive industry.
• Component review - analysed components to provide accurate machining hours and detailed cost breakdown.
Monnington Design Consultants, a design and manufacturing consultant specialising in bringing concepts to production. Responsibilities included the design, manufacture and assembly of prototypes as per the client’s specification. Business sectors have included deep sea research, pharmaceutical analysis and military applications.
• Client requirements - involved in preliminary customer manufacturing requirements and suggesting process improvements to reduce costs. Liaising with customers throughout the manufacturing process to ensure their expectations were surpassed.
• CAD - worked alongside clients to develop design concepts suitable for production.
• CAM - responsible for machining a variety of intricate metallic parts using 3 and 5 axis CNC machines. Programming was completed both online and offline.
• Inspection - 100% inspection of machined components using a variety of inspection instruments.
• Assembly - in house assembly of machined components as per assembly drawings.
Completed an apprenticship in Manufacturing Engineering whilst working full time.
• BEng Mechanical Engineering - 2:1 Upper Class • Dissertation investigating how maintenance intervals can be predicted; using condition based monitoring and spectrographic oil analysis. Working as a contractor for Arriva Trains Wales (part of the Arriva Group) my report provided maintenance period recommendations - 1st Class Award • Modules included - Business Management, Commercialising Innovation, Engineering Analysis, Introduction into Economics, Law, Accounting and Management services • Commercialising Innovation – created and presented a business plan for the development of a kinetically charged battery this included customer base and marketing methods
HND - Mechanical Engineering - Merit
HNC - Mechanical Engineering - Pass
BTEC Level 3 - Manufacturing Engineering - Double Distinction