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Lean Manufacturing Specialist / Consultant.
Paul Buckley MIET
,
Sandbach, United Kingdom
Experience
Other titles
Skills
I'm offering
Skilled Manufacturing Manager and Lean Specialist
A versatile, results driven manufacturing leader with over 20 years Automotive OEM experience developing exceptional leadership and people development skills. Humble relationship builder with suppliers, design teams, distribution and sales personnel as well as production teams from shop floor to senior leadership, implementing key efficiency and business improvement projects. Excelling in manufacturing process development for financial gain from Lean Manufacturing principles, tools and techniques. A highly developed data driven problem solving coach and team builder resolving key production issues.
Available for short to mid term engagements.
A versatile, results driven manufacturing leader with over 20 years Automotive OEM experience developing exceptional leadership and people development skills. Humble relationship builder with suppliers, design teams, distribution and sales personnel as well as production teams from shop floor to senior leadership, implementing key efficiency and business improvement projects. Excelling in manufacturing process development for financial gain from Lean Manufacturing principles, tools and techniques. A highly developed data driven problem solving coach and team builder resolving key production issues.
Available for short to mid term engagements.
Markets
United Kingdom
Germany
Denmark
Norway
Sweden
Finland
Language
English
Fluently
Ready for
Ongoing relation / part-time
Full time contractor
Available
My experience
2019 - ?
freelance
Manufacturing Specialist /Consultant
MAG19 Limited.
Available for appropriate role - Lean Manufacturing Coach, Manufacturing leadership, Quality leadership,
Continuous Improvement leadership, (employing lean principles, methodologies and tools).
Continuous Improvement leadership, (employing lean principles, methodologies and tools).
Lean, Continuous improvement, Leadership, Lean Manufacturing, Coach
2012 - 2019
job
Vehicle Quality Manager
Jaguar Land Rover.
• Achieved plant wide accreditation to TS16949 standards by in-house audit and resolution of non compliances with relevant teams.
• Reduced warranty claims by 70% over a 12-month period from improvement strategies prioritising internal RFT and external warranty data.
• Implemented regular shop floor team reviews to establish excellent levels of engagement and high-performance in my team of 60-80 staff including engineers, skilled and semi-skilled associates (annual “Pulse” survey improvements).
• Made a 20% reduction in cost per car (labour & overhead), using CCAR, 8D and 6 sigma associate led process efficiencies and cost down projects.
• Ensured all vehicles conform to legal and homologation requirements for their respective markets.
• Reduced in-production defects by >15% annually from coaching cross functional teams (inc supplier teams) for quality and flow problem-solving, embedding learning into daily production, eliminating errors, & reducing rework.
• Improved RFT by 30% through design and implementation of new processes to meet specific production quality constraints within current model and new model introduction.
• Identified and applied campaigns for known Safety/ Legal and Quality escapes to effectively hold and process vehicles in the distribution system. Ensured all reworks were carried out to standard and that costs were allocated back to the point of error supplier or process.
• Eliminated in plant cost for supplier reworks using third party inspection and rework on finished vehicle as well as incoming parts inspection non compliance
• Reduced warranty claims by 70% over a 12-month period from improvement strategies prioritising internal RFT and external warranty data.
• Implemented regular shop floor team reviews to establish excellent levels of engagement and high-performance in my team of 60-80 staff including engineers, skilled and semi-skilled associates (annual “Pulse” survey improvements).
• Made a 20% reduction in cost per car (labour & overhead), using CCAR, 8D and 6 sigma associate led process efficiencies and cost down projects.
• Ensured all vehicles conform to legal and homologation requirements for their respective markets.
• Reduced in-production defects by >15% annually from coaching cross functional teams (inc supplier teams) for quality and flow problem-solving, embedding learning into daily production, eliminating errors, & reducing rework.
• Improved RFT by 30% through design and implementation of new processes to meet specific production quality constraints within current model and new model introduction.
• Identified and applied campaigns for known Safety/ Legal and Quality escapes to effectively hold and process vehicles in the distribution system. Ensured all reworks were carried out to standard and that costs were allocated back to the point of error supplier or process.
• Eliminated in plant cost for supplier reworks using third party inspection and rework on finished vehicle as well as incoming parts inspection non compliance
Quality systems, People Manager, Coaching & Problem Solving, Customer focus, Warranty reduction, Quality assurance, Quality Standards, Auditing, New Model Planning
2008 - 2012
job
Lean Learning Academy Manager
Jaguar Land Rover.
Development of lean manufacturing into the production system. Coaching of leadership teams through academy courses and shop floor reviews. Creating a “tomorrow better than today” culture which delivered continuous improvement to SQDCME metrics.
Leadership Coaching, Lean Manufacturing, Problem solving, Value stream mapping, Policy deployment, Standardised work, Error proofing, Line balancing
2003 - 2008
job
Production Manager
Jaguar Land Rover.
Leading shift production, responsible for SQDCME deliverables with a team of circa 120 employees.
Introduction of new models and new processes delivering improving efficiency and quality.
Introduction of new models and new processes delivering improving efficiency and quality.
Team Leadership, Negotiation, Change management
2001 - 2003
job
Manufacturing specialist
Jaguar Land Rover.
Introducing lean manufacturing techniques and principles into paint process
Production engineering, Quality Engineering, People management, Standardised work, Problem solving, Automation
1998 - 2001
job
Paint Process Engineer
Vauxhall Motors.
Automation processes, Paint
technology monitoring and reaction processes, team leadership.
technology monitoring and reaction processes, team leadership.
Team Leadership, Automation, Leadership, Technology, Monitoring, Processes
1995 - 1998
job
Manufacturing engineer
Foden Trucks.
1995 - 1998
job
Manufacturing engineer
Foden Trucks.
1979 - 1989
internship
Apprentice - Engineer
British Coal, Prince of Wales Colliery Pontefract.
Installing and maintaining surface and underground mining machinery.
My education
1989
-
1993
University of Huddersfield
Bachelors (2:1 hons), Engineering systems - Manufacturing
Bachelors (2:1 hons), Engineering systems - Manufacturing
1979
-
1985
Whitwood Technical Collage
B.Tec, National
B.Tec, National
1974
-
1979
Kings School Pontefract
GCSE O level, Maths Physics Chemistry Geography Metalwork
GCSE O level, Maths Physics Chemistry Geography Metalwork
Leeds Metropolitan University
MSc, Manufacturing Management
MSc, Manufacturing Management
?
-
1988
City AND Guilds Hydraulics AND Pneumatics
N/a, N/a
N/a, N/a
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