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Lean and Improvement expert specialising in increased productivity through culture change.
Ian Whyld
,
Nottingham, United Kingdom
Experience
Other titles
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I'm offering
As a former Global Head of Improvement for a Blue Chip manufacturing company, I specialise in deploying sustained business culture change to implement Lean principles and deliver significant operational improvements. My leadership style is one predominantly focused around coaching. This enables individuals to be the best they can be; learning how to resolve issues and implement improvements themselves, rather than being directed.
Markets
United Kingdom
Language
English
Fluently
Ready for
Larger project
Ongoing relation / part-time
Available
My experience
2017 - 2019
job
Head of Continuous Improvement - Procurement and Installations (P&I)
Rolls-Royce plc.
Responsibilities: -
● Accountable for the improvement strategy across 1400 people within the global P&I organization.
● Deployment of the Rolls-Royce Production System into 2 manufacturing plants (~650 employees). Through deployment of the following activities, I have reduced the missed customer orders from £8M to £5.3M: - A FIFO Shop floor control system, a lean training program for shop floor workers, plant based problem solving, a competence management system, a set of shop floor standards, a standard diary (with correct behaviours), a compliance checking structure, value stream mapping, bottleneck management and shop floor visual management.
● For the External Supply Chain business unit, I have delivered a program of work which resolved the top 3 biggest issues the supplier management teams had. These included: -
Creating a Business Intelligence system to provide data for teams to make decisions on vendor performance, a visual management system to control short interval control issues with product delivery, an update to the SMT Production System to simplify the requirements and a standard diary structure. The results of these and other improvement work has reduced the number of missed orders from our EU supply chain from a peak of
£13.4M (Aug) to £10.5 at year end.
● Delivered 3 Major Quality Investigations to provide robust root cause resolution of 3 issues within the Installations Supply Chain. These included a £20M escape, a £5M escape and a significant issue that compromised the relationship with our customer.
● Accountable for leading the Quality System requirements for the start up of a new production facility based in the Advanced Manufacturing Facility in Rotherham to achieve CAA approval by mid 2020.
● Accountable for the improvement strategy across 1400 people within the global P&I organization.
● Deployment of the Rolls-Royce Production System into 2 manufacturing plants (~650 employees). Through deployment of the following activities, I have reduced the missed customer orders from £8M to £5.3M: - A FIFO Shop floor control system, a lean training program for shop floor workers, plant based problem solving, a competence management system, a set of shop floor standards, a standard diary (with correct behaviours), a compliance checking structure, value stream mapping, bottleneck management and shop floor visual management.
● For the External Supply Chain business unit, I have delivered a program of work which resolved the top 3 biggest issues the supplier management teams had. These included: -
Creating a Business Intelligence system to provide data for teams to make decisions on vendor performance, a visual management system to control short interval control issues with product delivery, an update to the SMT Production System to simplify the requirements and a standard diary structure. The results of these and other improvement work has reduced the number of missed orders from our EU supply chain from a peak of
£13.4M (Aug) to £10.5 at year end.
● Delivered 3 Major Quality Investigations to provide robust root cause resolution of 3 issues within the Installations Supply Chain. These included a £20M escape, a £5M escape and a significant issue that compromised the relationship with our customer.
● Accountable for leading the Quality System requirements for the start up of a new production facility based in the Advanced Manufacturing Facility in Rotherham to achieve CAA approval by mid 2020.
Business Intelligence, Training, Lean, Procurement, Continuous improvement, Management, Compliance, Production, Value stream mapping, Culture, Problem solving
2015 - 2017
job
Global Head of Continuous Improvement
Rolls-Royce.
Define and deliver the global continuous improvement strategy for RR.
Created Sector level goals for the cost of non-quality and provided business KPIs to track and progress the business progress.
Owned the global problem solving strategy for RR – delivering tools and competence to meet the business demands needs.
Created and delivered a tool and training for cell level problem solving techniques.
Wrote and deployed the process for RR’s Strategy creation and Business Plan Deployment (BPD).
Created Sector level goals for the cost of non-quality and provided business KPIs to track and progress the business progress.
Owned the global problem solving strategy for RR – delivering tools and competence to meet the business demands needs.
Created and delivered a tool and training for cell level problem solving techniques.
Wrote and deployed the process for RR’s Strategy creation and Business Plan Deployment (BPD).
Strategy, Training and Training Documentation, Strategy and business development, Executive coaching
2013 - 2015
job
Head of Improvement
Rolls-Royce.
Deliver a portfolio of improvement activities to exceed the £10M cost saving target – ultimately delivering £13.7M cost savings within the year. These improvement activities involved analyzing the value-stream, identifying the highest levels of spend, and creating innovative solutions to resolve them. These included :–
A new transportation method that halved airfreight costs by consuming half the number of pallet spaces
A new method of vacuum packaging engines to reduce repair costs
Extending the life of engine parts through data analysis
Using statistical in-service data to justify a widening of vibration acceptance levels and reduce engine rejection levels.
Creating a communications strategy for the BPD to engage the 150 project staff and align them with the strategic targets.
A new transportation method that halved airfreight costs by consuming half the number of pallet spaces
A new method of vacuum packaging engines to reduce repair costs
Extending the life of engine parts through data analysis
Using statistical in-service data to justify a widening of vibration acceptance levels and reduce engine rejection levels.
Creating a communications strategy for the BPD to engage the 150 project staff and align them with the strategic targets.
Project Management, Team Leadership, Project planning
2010 - 2013
job
Head of Quality
Rolls-Royce.
Ensure that the quality of the released product meets the required Rolls-Royce specifications, whilst still supporting the committed delivery schedule.
Owned and maintained the Production Test Quality Management system to ensure CAA approvals to deliver to Part 21 requirements
Accountable for the internal audit program against internal standards in order to meet AS9100 approval.
Manage and define the strategy for the Quality Assurance population in Large New Engine Production.
Lead the Quality organization consisting of 32 individuals. Ensure a structure is in place to provide 24/7 support to the facility, whilst also improving the organizational competence
Ensure robust root cause resolution of any customer complaints and quality failures, including personally delivering Major Quality Investigations.
Owned and maintained the Production Test Quality Management system to ensure CAA approvals to deliver to Part 21 requirements
Accountable for the internal audit program against internal standards in order to meet AS9100 approval.
Manage and define the strategy for the Quality Assurance population in Large New Engine Production.
Lead the Quality organization consisting of 32 individuals. Ensure a structure is in place to provide 24/7 support to the facility, whilst also improving the organizational competence
Ensure robust root cause resolution of any customer complaints and quality failures, including personally delivering Major Quality Investigations.
Quality Management, ISO 9001 quality management, Problem solving, Quality assurance
My education
1998
-
2002
Bristol University
Masters, Aerospace Engineering
Masters, Aerospace Engineering
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