Howard Sewell Email & Phone Number

Colchester, England, United Kingdom

Responsible for the development of PSOE (Plexus System of Operational Excellence) model and creating systems and documentation to support deployment globally and to assess the level of maturity of sites globally.Developed an industry standard APQP model supporting design engineering, manufacturing, quality, transition management etc to support automotive, aerospace and medical standards and is fully configurable according to business sector, project size and level of complexity.Leading the development of new training based on an Operational Excellence model supporting People Engagement, Lean Manufacturing and Zero Defect Quality pillars.Develop new Problem Solving Tools training to support Zero Defect Quality and the CAPA/8D system (AGILE based).Develop new Lean Practitioner Training modules including Value Stream Mapping, Cell Design, Line Balancing, Kanban, Standard Work, Gemba Walk and Ohno Circles; Introduction to Lean Manufacturing, Process and Performance Capability, SPC and Control Charts, Yellow Belt, Seven Basic Basic Tools of Quality and Green Belt.Organise ASQ and BQF Six Sigma/Lean Six Sigma Black Belt Certification training. Support, coach, mentor individuals through to certification.Leading and facilitating strategic customer focused Lean Workshops and Continuous Improvement projects to eliminate waste and improve value stream margins, increase productivity and velocity, reduce WOCT and drive customer cost reductions.Support and facilitate Kaizen Events and DMAIC/DMADV improvement projects globally.Work with global teams to create working systems that operate in different cultural environments.Manage the annual BEST (Bringing Employee Successes Together) Competition that identifies and promotes Continuous Improvement projects and drives Best Practice Sharing globally, resulting in $5 million hard savings annually.

Oradea, Bihor, Romania

Responsible for transition of medical products from Abbot and Alere Toxicolgy to Plexus, Penang.Worked with the Penang Manufacturing Team to ensure Transition Plan is followed and conducted weekly customer reviews to ensure compliance with Engineering Sample Build requirements, Verification & Validation and IQ/OQ/PQ protocols.Focus on Customer Continuous Improvement activities to provide customer cost reductions and value stream margin improvements.Facilitated medical customer Lean Workshop (including Value Stream Mapping) to identify and eliminate wastes and to identify and correct process deviations.Conduct Lean Training to Engineering Solutions and Manufacturing Solutions personnel to support the ONE PLEXUS strategy.Project Leader for the Full Value Stream Phase Review Model (6 Stage Gate APQP Model) alignment between Engineering Solutions and Manufacturing Solutions.

Oradea

Responsible for managing the LSS (Lean Six Sigma) deployment in the EMEA Region covering three manufacturing sites in Scotland and Romania. Also provide support in Penang, Malaysia and Xiamen, China. Travel globally 90% of time.Developed and implemented Lean Index Assessment Maturity Model to standardize Lean Line Certification.Drive PSOE (Plexus System of Operational Excellence) across all sites. I was part of the Team that developed and deployed the PSOE Model.Conduct formal PSOE Assessments and agree Continuous Improvement Roadmap with site Management Teams.Facilitate and conduct training in 5S, VSM, SPC, FMEA, Poka Yoke, Kaizen Facilitator, Quality Tools and advanced Statistical Tools.Provide training to Black Belt, Green Belt and Yellow Belt candidates.Provide coaching and mentoring in support of Black Belt and Green Belt projects.Develop and deploy QRQC (Quick Response Quality Control) and develop Problem Solving Training for Operator Level, Technician Level, Engineering and Management Levels.Train, facilitate, coach and mentor team members on CAPA/8D process.Developed an enhanced 6 stage Gate APQP Model that is scalable based on business sector, size and complexity of project. Fully compliant with AS9145:2016 Aerospace APQP Model, AS9100:2016 Rev D, SO13485:2016 and ISO9001:2015.Report financial savings in terms of hard and soft savings in the Lean Steering Committee and Quarterly Operations Review.Facilitate and participate in joint Kaizen events with customers in EMEA and APAC.Conduct Financial Reviews with Site Controller and Management Team to identify gaps in P&L to drive Continuous Improvement activities.Participate in Regional reviews to define Lean Six Sigma deployment strategy.Provide coaching and support to BEST (Bringing Employee Suggestions Together) Practice Competition participants to standardize processes in line with the One Plexus vision.

Oradea, Romania

Responsible for managing the LSS (Lean Six Sigma) department at Site Level.Conduct Yellow and Green Belt Training and provide coaching and mentoring to Green Belt Candidates.Responsible for the deployment of Lean Six Sigma initiatives based on the Hoshin Plan.Set up Lean Six Sigma Steering Committee to review and agree deployment of LSS activities, prioritise Lean Sigma projects, report training status, 5S status, hard and soft savings and conduct DMAIC Report Out presentations.Conduct Tollgate Reviews for DMAIC/DMADV projects.Participated in the team that developed the financial model for calculating and reporting hard and soft savings.Part of the team that developed the PSOE (Plexus System of Operational Excellence) that consists of four Areas of Focus underpinned by 15 core measurements. Conduct PSOE Assessments to identify areas of improvement.Responsible for the Lean Six Sigma Hoshin Plan and Bowling Charts.Schedule and participate in Gemba Walks to identify Continuous Improvement opportunities.Plan the 5S Audit schedule and participate in the 5S Audits across the ten key site areas.Participate and facilitate Green belt projects to provide hard savings that are then locked into the P&L forecast.Provide Customer Lean Six Sigma Status presentations including deployment of LSS initiatives and reporting of completed DMAIC, A3 and Kaizen Blitz projects.Responsible for deploying Visual Management, One Piece Flow including Supermarket and Kanban material management.Conduct Kaizen Events based on improvement activities identified in the current state VSM (Value Stream Map)

Tiszaujvaros, Hungary

Responsible for managing the LSS (Lean Six Sigma) department at Plant Level in a matrix management organization.Manage the LSS Team comprising of the Black Belt Project Leader, Green Belts and Administrator and indirectly manage Kaizen Technicians in the Moon Shine Area.Responsible for the deployment of Lean training based on Jabil Corporate practices including coaching and mentoring of candidates through training modules, final exam and five certification projects.Deploying DL Awareness Training across all BU’s and successfully implemented the DL Suggestion System including tracking of suggestion status.Support Green Belt and Black Belt certification program through ASQ.Responsible for managing and supporting Lean projects with validated savings of $13.8 million in FY11.Set up and manage Lean Council holding monthly meetings monitoring core KPI’s and Lean Deployment Plans.Conduct Lean Index Assessments to evaluate site progress and identify opportunities for improvement. Prioritise Kaizen events based on customer and business requirements and approve through the Lean Council.Manage and present customer Operational Excellence Reviews focusing on number of Kaizen events, summary of completed projects, manufacturing cost reductions and training status.

Burnsville, Minnesota, Usa

Multi functional responsibility with global responsibility for all environmental compliance initiatives and managing engineering and quality related projects. Successfully project managed the implementation of the Quality Management System (QMS) for ISO 9001:2000, ISO9001:2008 and AS 9100:2004 Rev B (Aerospace) certification for Corporate Headquarters in the US and assisted Hermosillo (Mexico) Manufacturing Plant to achieve AS9100 certification.ASQ Certified Lead Auditor for AS9100:2004 Rev B, ISO 9001:2008 and ISO 14001:2004.Successfully project managed the implementation of the Environmental Management System (EMS) for ISO 14001 Certification for Corporate Headquarters.Manage all AS9100, ISO 9001 and ISO 14001 Internal Audits including Audit Team consisting of five Lead Auditors and six Co Auditors. Provide guidance and ensure everyone completes Audit Reports, Non Conformance Reports. Manage and monitor Corrective Action Plan including management team briefing sessions and reviews.Implemented OHSMS (Occupational Health and Safety Management System) in line with OHSAS 18001.Define and implement strategies to ensure compliance with all global environmental legislation including EU RoHS, China RoHS, WEEE, REACH, Packaging and Battery directives. DfE Coordinator for Communications Systems globally.Ensure compliance with the RoHS, REACH, WEEE, Packaging and Battery Directives are implemented at all manufacturing sites worldwide including the management of potential non compliant inventory exposure, material segregation, dual SKU manufacturing and conduct internal RoHS compliance audits.Implemented GEMS (Global Environmental Management System) to manage collection of Bosch N2580, Certificates of Compliance and IPC 1752-2 Class 6 Material Declarations for EU RoHS, China RoHS, REACH, Packaging and Battery. Provides visual user interface that allows easy BOM audits to be conducted to verify compliance.

Hong Kong

Responsible for standardising quality assurance methodologies across all three divisions comprising of twelve individual manufacturing sites.Responsible for ISO 9001:2000, QS-9000, implementation of ISO/TS 16949:2002 and ISO 14001.Outline and implement strategies to achieve compliance with the Restriction of Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive (2002/95/EC) by 1st July 2006. Evaluate current data acquisition and utilisation to initiate a standardised Quality Gate system.Generate and implement process enhancement strategies based on Cost of Quality model.Evaluate and improve PPAP (Production Part Approval Process) methodology for automotive customers.Implement customer complaint tracking system database to ensure all CAR (Corrective Action Reports) and 8D reports are completed in a timely manner and to provide performance metrics.

Kidderminster, England

Responsible for the evaluation and proposal of a new Surface Mount Assembly facility in the Kidderminster manufacturing site that meets the manufacturing process requirements in compliance with the legislation for the Restriction of Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive (2002/95/EC) by 1st July 2006. Evaluate and benchmark surface mount equipment, including screen print, pick and place, reflow ovens, AOI (Automatic Optical Inspection) and handling equipment to enable RoHS (Restriction of Hazardous Substances) compliant assemblies to be manufactured.Identify and provide training with respect to RoHS compliant PCB (Printed Circuit Board) process requirements and ensure component compliance data in the form of Certificates of Compliance and Full Material declarations are archived to a suitable compliance data management system.Project manage the evaluation, purchase, negotiation, personnel selection and training, service requirements, installation and commissioning of the new surface mount facility.Technology transfer of high volume products to China.Conduct RoHS compliance and Process Audits on strategic suppliers in UK and China. Design and implement optimised production line with all material on Kanban fed direct to line.

Birmingham, England

Supervised component kitting and provided Process Engineering supportResponsible for standardising the nomenclature and parts data libraries for all component variants used in Fujitsu’s PCB assembly plant utilising PanaPro IPO to optimise programmes for Panasonic MSF. Line configurations based on DEK screen printers, Fuji CP4, CP642/643 and Panasonic MSF.Ensured that all programmes were generated with new parts data libraries.Responsible for controlling PCBA NPI’s, debugging programmes, parts data and process related issues over weekend shifts.

Isle Of White, England

Identified production losses within the surface mount area and implemented corrective actions to optimise production throughput. Introduced metrics including total time lost, breakdown, number of placements, attrition and O.E.E. (Overall Equipment Effectiveness)Introduced SMED principles to allow quick changeover techniques using quick-change carts. Reduced changeover time from four hours to twenty minutes.Introduced bar code verification for offline feeder setup and feeder changes as a result of component exhausts effectively eliminating incorrect reels being loaded.

Birmingham, United Kingdom

Responsible for surface mount optimisation and standardising nomenclature and parts data libraries for all component variants used in Fujitsu’s PCB assembly plant utilising PanaPro IPO to optimise programmes for Panasonic MSF. Line configurations based on DEK screen printers, Fuji CP4, CP642/643 and Panasonic MSF.Responsible for running NPI’s, debugging programmes, parts data and process related issues.Weekend surface mount assembly area shift supervisor.

Cavite, Philippines

Directed Quality Assurance in a multi-site operation based in Philippines, China and USA. Operationally responsible for Quality Engineering, In-Process Quality Control, NPI Quality Engineering and Quality Control, SPC Engineering, Quality Systems and Product Safety. Functionally responsible for the rest of manufacturing.Implemented culture change in Asia resulting in quality orientated, empowered workforce operating Lean Manufacturing. Six Sigma Champion, initiated and drove Six Sigma DMAIC programme to Green Belt, underpinned with training in SPC, Ishikawa, Poke Yoke, 5 Why and DoE (Design of Experiment).Travelled worldwide directly interfacing with strategic customers to present and review in-process quality data including Continuous Improvement plan.Managed RMA’s (Return Material Authorisation) and designed proof of screen life acceleration tests, collection and analysis of data and review with customers such as Fujitsu, Japan; Agilent, Germany and Cisco, USA.Quality Assurance was responsible for generating proof of screen for reliability testing based on Environmental Stress Screening (ESS), performing Long Life Tests and Highly Accelerated Life Testing (HALT). All chargeable time to failure data was plotted in a Weibull Analysis to predict infant mortality, intrinsic failure or end of life failure modes.Drove Quality programme within the Stage Gate Process of New Product Introductions and Technology Transfers. Ensured complete process qualification prior to transfer and introduced operational Quality Gate System linked to the HyperTrack Shop Floor Data Collection system.Part of the team established to review the NPI Stage Gate Process documentation and procedures.Managed ISO 9001, ISO 14001 including regular system audits and preparation for implementation of ISO 9000:2000.

Abingdon, Oxford, England

• Directed engineering teams to effectively manage Technology Transfer, New Product Introduction, Automated Manufacturing, Sub-Contract and Systems Management.• Full CAPEX responsibility including generation and control of $22 million budget. Part of team responsible for generating Business Continuity Plan.• Responsible for generating Technology Transfer and Vendor Assessment methodologies.• Developed proposals for clean room compliant, automated robotic chip prep line comprising of Hirata Cartesian/SCARA robots, die shuttles, resist strip and clean, Automatic Optical Inspection and anti-reflective coating.• Facilitated bench marking exercises on wafer and die handling equipment in Japan and USA.• Evaluated and procured batch and in-line VFM (Variable Frequency Microwave) systems reducing typical die attach cure times by factor of X10.

Redditch, England

• Reported to the Technical Director and tasked with analysing surface mount efficiencies to ensure manufacturing forecast achievable.• Reconfigured Panasonic surface mount line operating fixed feeder set up to quick changeover format operating in Prep Mode. Utilising PanaPRO IPO (Interactive Process Optimisation) and PanaPRO CVT (Component Verification Tracking); achieved measured efficiency improvements averaging 33 percent. Surface Mount equipment comprised of Panasonic MVIIVb, MVIIC’s and MPA G1’s.• Set up new feeder Kanban to facilitate quick changeover while the Panasert surface mount equipment was operated in Prep Mode. • Project managed specification, negotiation, purchase, factory floor layout and installation for new Panasonic MVIIVb as part of line reconfiguration enabling implementation of a number of new products introductions.• Utilising 8D problem solving methodology, introduced SPC, regular flux titrations, scatter charts and PM schedules resulting in reduction of wave soldering defect rates from 6,000 ppm to 500 ppm.

Kidsgrove, England

• Managed Operations of DELL Strategic Business Unit to achieve EBIT and Customer On Time Delivery with $180 million turnover and $15 million added value.• Production of DELL workstations and server products based on four single sided and one double sided surface mount lines. Lines comprised of three Panasonic MVIIF/MVIIV chip shooters and one MPAVII i/c placement system and double sided line comprised five Panasonic MVIIF/MVIIV and one MPAVII. The reflow process was based around BTU, while wave soldering was processed through the Electrovert Electra.• Responsible for manufacturing team of 250 with six direct reports operating within unionised work environment.• Managed New Product Introduction of three new server boards with associated risers. • Part of team evaluating odd form component insertion, primarily PMJ Odd Form Insertion System, based on a standard Cartesian set up, utilising the ADEPT controller and Universal Instruments Odd Form system based on the GSM I platform. System evaluated on components such as DIMMS, RIMMS, Slots and various other connector types.

Aylesbury, England

• Responsible for all aspects of Production including Planning, Quality Control, Process Engineering and Test. • Restructured personnel and re-engineered factory layout implementing 5S and Total Productive Maintenance.• Achieved improved material handling utilising Kanban principles and working closely with suppliers resulting in improved deliveries and piece part quality.• Rebalanced production cells and improved workstation ergonomics improving production output of Mast Head Amplifiers and Boosters for use within the telecommunications industry. Introduced enabling metrics.

Newtown, Wales

• Responsible for managing, mentoring and motivating engineering teams totalling 73 engineers including Process Engineering, Industrial Engineering, Production Engineering, Test, Facilities and Maintenance Engineering. • Full responsibility for $9 million CAPEX and Repairs/Renewals budgets including control and reporting of budgets at monthly at Operations Review Meeting. • Project managed erection of new manufacturing site incorporating PCB Assembly, Materials Sequencing Unit and re-engineered the existing Final Assembly Plant including elevated soaks, pre-soaks, new OMRON PLC based control systems; touch screen MMI (Man Machine Interfaces) and intelligent auto-routed palletised transfer systems. • Working in a Continuous Improvement, team orientated environment, introduced TPM, 5S, OEE, Poke Yoke and SMED Lean principles.• Reconfigured all surface mount lines from fixed feeder set up to custom feeder set up in line with SMED principles including installation of PanaPRO IPO (Interactive Process Optimisation) and PanaPRO CVT (Component Verification Tracking). Reduced changeover times to less than ten minutes. • Managed projects including the design and installation of a Finished Goods Automatic Search and Retrieve System including two Component Stores and Bulk Store, Pick To Light assisted kitting lines, electronic Kanban that automatically replenished bins based on minimum stock quantities and ROP (Re-Order Point) quantities, linked to the Warehouse Computer System, MRP and to suppliers via EDI (Electronic Data Interchange).• Manufacturing systems projects managed included purchase of new Universal 4791 and 4796 chip shooters, GSM I and II placement systems, Panasonic MVIIF chip shooter, re-engineering of existing systems, in-line Viscom AOI’s, SCADA (Supervisory Control And Data Acquisition) system, automated bar code application system, AGV’s (Automatic Guided Vehicles), and capacity constraints analysis model.

Ipswich, England

• Set up new UK based subsidiary company providing sales, marketing and technical support for Automatic Optical Inspection systems for populated PCBA’s.• Lectured at seminars around the world and attended exhibitions such as NEPCON West, Productronica etc.• Visited customers around the world to define and implement complex manufacturing solutions, provide system installation, training and programming utilising off-line CAD data.• Conducted customer demonstrations in the UK or US demonstration centres or at customer sites. • Provided consulting service for configuring and optimizing PCBA manufacturing processes at IBM Scotland; Ericsson, UK; Matra Ericsson Telecommunique, France; Nokia, Finland; DEC Ireland; Apple, Ireland and ICL England.• Provided support in developing and installing the first semi-automated light guided repair cell utilizing a Logpoint light guided assembly cell networked to the AOI. Defect component coordinate data was downloaded to automatically point to manufacturing defect on the PCBA and automatically present the correct replacement component to the operator.

Felixstowe, England

• Responsible for managing the Industrial Engineering team.• Set up dedicated Pre-Production facility including dedicated SMT (Surface Mount Technology) Line, an auto insertion line including DIP, Axial and Radial Insertion and Final Assembly and Test cells. • Established effective methodologies for New Product Introduction programme within high volume manufacturer of solid-state meters.• Project managed the design, development and installation of an auto-routed final assembly transfer system that included twelve Hirata Cartesian and SCARA robot cells. Included palletised server and auto programme select via bar code product identification. Responsible for debugging control software of palletised transfer system and robot cells at Hirata in Kumamoto, Japan.• Introduced new SMD assembly line including in-line robotic DIP inserter, Universal Ultraplace chip shooter, Universal OmniB for placement of fine pitch QFP’s, PLCC’s and SOIC’s and Automatic Board Handler enabling totally random access of PCB’s. Introduced Automatic Board Handlers to second Universal line providing direct interface and full random exchange of boards between lines. Lines were capable of batch sizes of one if required.• Conducted evaluations of Automatic Optical Inspection (AOI) systems and laser inspection systems for PCBA’s.• Managed the organisation and control of all advanced manufacturing projects including resource allocation and budgetary control.

Colchester, England

• Responsible for production and prototype testing and debugging of high-speed SMD (Surface Mount Device) chip shooters and flexible pick and place systems for the PCB manufacturing industry.• Responsible for performing Quality Assurance testing of surface mount assembly equipment, die-sort loaders, die-bonders, bond strength testers and Multicore Universal Solderabilty Testers (MUST).• Performed customer demonstrations, customer programming and maintenance training• Performed system installations and integration in the UK and USA.• Provided equipment service and programming support.

Master Of Business Administration (M.B.A.)

Higher National Diploma, Systems Engineering