www.lewispies.co.uk

www.lewispies.co.uk

Currently, I am working within Principality Consulting's e-business work and helping to expand their lean manufacturing sector to include Lean/ Innovation Diagnostic Tendering in Wales. For 8 months I worked as an Associate Member Consultant with a UK based logistics expert, I was part of a team investigating the implementation of a multi-million pound factory for a global medical company in Europe. My area within the assembly area included fully understanding the current operation and… Show more Currently, I am working within Principality Consulting's e-business work and helping to expand their lean manufacturing sector to include Lean/ Innovation Diagnostic Tendering in Wales. For 8 months I worked as an Associate Member Consultant with a UK based logistics expert, I was part of a team investigating the implementation of a multi-million pound factory for a global medical company in Europe. My area within the assembly area included fully understanding the current operation and running off-site trials/ workshops to generate improvement ideas for the final design. Our team provided a document to allow two multi-national factory automation and logistics specialists to provide quotations for the new factory.Within the Morgan Group I facilitated a factory up-lift by installing best practice: Using Pareto, process flow and area timings developed improvement plans for them to further improve the area. Both output and story boards were employed to improve the areas visual management and a 30% improvement was gained to their bottleneck process.Major layout changes were completed to the Swansea brush area gaining an overall 50% in space saving allowing the movement of a CNC area which significantly reduced transport waste and facilitated the turning off of an expensive dust extraction plant. Show less

Initially, I was Project Managing factory transfers and consolidation within the Swansea Plant: To accommodate the transfer of an existing Morgan UK and German operation within Swansea I had to consolidate the Swansea footprint by 25%. I then became the member of a team that created a new MOD Armour facility within the Swansea plant for the production of body armour for the troops in Iraq. I provided the Assembly Process employing Pokayoke (fail-safe) techniques to ensure the packs… Show more Initially, I was Project Managing factory transfers and consolidation within the Swansea Plant: To accommodate the transfer of an existing Morgan UK and German operation within Swansea I had to consolidate the Swansea footprint by 25%. I then became the member of a team that created a new MOD Armour facility within the Swansea plant for the production of body armour for the troops in Iraq. I provided the Assembly Process employing Pokayoke (fail-safe) techniques to ensure the packs were assembled correctly. Finally, I became the Lean Manufacturing Engineer for the Swansea Plant initiating process mapping followed by Kaizen and 5's activities. I ran an international Kaizen week with four other Morgan European plants on our carbon brush lines.I further developed Story Boards that demonstrated all the area improvements further enhancing the area visual management. Show less

I was part of the Executive Management team running a £120M turnover company manufacturing 3.7M heat exchange parts for the automotive industry within the Calsonic Kansei Group.I ran the Program Management, Process and Manufacturing Engineering and Maintenance departments for 9 years.• My Team Provided heat exchange parts ( radiator/ oil cooler / condenser / evaporator) and systems to successfully launch new Mini, Primera, Micra, Freelander, Discovery, Astra, Peugeot 406, Fonterra, Audi… Show more I was part of the Executive Management team running a £120M turnover company manufacturing 3.7M heat exchange parts for the automotive industry within the Calsonic Kansei Group.I ran the Program Management, Process and Manufacturing Engineering and Maintenance departments for 9 years.• My Team Provided heat exchange parts ( radiator/ oil cooler / condenser / evaporator) and systems to successfully launch new Mini, Primera, Micra, Freelander, Discovery, Astra, Peugeot 406, Fonterra, Audi A4 &A6, Volvo V40 and SAAB 95 along with numerous face lifts to these and other cars.• As part of Management Team we achieved company cost down targets of approximately £6M per year initiating Kaizen and Lean activities towards one piece flow. I presented our proposals to the main board in Tokyo for them to approve.• Responsible for continuous technology transfer between Japan, UK, Spain and Polish facilities. I visited the major plants in Japan to enable us to benchmark and transfer their best manufacturing solutions and Kaizen ideas and the methodology to achieve this. Show less

Responsible for all Engineering at the Trowbridge factory, I changed a 23 member team from a fire fighting role into a process support and improvement role. We implemented preventative maintenance, Kaizen teams to reduce budgets by 35% and supported the introduction of cell manufacturing based on customer order instead of large batch manufacture.I completed an MBA and asked to work overseas. I was seconded to the Czech Republic for 5 months to uplift the quality and capability of a new… Show more Responsible for all Engineering at the Trowbridge factory, I changed a 23 member team from a fire fighting role into a process support and improvement role. We implemented preventative maintenance, Kaizen teams to reduce budgets by 35% and supported the introduction of cell manufacturing based on customer order instead of large batch manufacture.I completed an MBA and asked to work overseas. I was seconded to the Czech Republic for 5 months to uplift the quality and capability of a new acquisition from former Eastern Bloc mentality to a Western approach. Avon-Rubena gained full VW accreditation in Feb 94.I was then sent to Portugal to select a location, partners and provide a 4000m sqd hose plant. I designed the layouts, purchased the plant equipment and we started production in March 96. It is currently doubled in size and still providing automotive hose within Europe. Show less

I was part of a Divisional Engineering Team responsible for two plants in South Wales and Co. Durham. I helped improve face mask production, provide a new plastics extrusion line, completed a major powder/ liquid feed automation programme and established a large scale laboratory for manufacture and testing of new video tape formulations. I gained my first experience of real project management within a large multi-national.