Projects and Case Studies

UK-Based Nuclear Facility

The project responsibilities:-

Reporting to the Engineering Director, this role is responsible for the design, manufacturing and construction of equipment to decommission an end of live nuclear facility. This role is responsible for managing a team of multi-disciplined engineers, designers, and test and commissioning engineers, systems control engineers, project managers, project planners, manufacturing engineers and sub contract construction companies. Day to day accountabilities are to Chair design / constructability reviews, engineering appraisal and initial design reviews concept designs, managing stake holders.


UK-Based Steel Manufacturer

The project responsibilities:-

To professionally manage the manufacturing operations of Steel manufacturer circa 120 engineers, fabricators and welders. The role ensures projects are delivered to cost, schedule and the specified quality requirements. In addition to this, develop and introduce Continuous Improvements in relation to the way projects are executed. Establish and maintain positive and effective working relationships with all customers in order to gain an understanding of their needs to strengthen customer relationships. Manage internal & supplier relationships in a professional and effective manner. Full project delivery and P&L accountability for all relevant projects (circa £5-£10m p.a.) Provide leadership and direction to a team of Contract Managers, Project Engineers, Planners, and Support Staff etc. in the execution of Projects. Ensure that projects comply fully with all statutory and regulatory requirements. Ensure project change control procedures are established and adhered to. Manage and actively mitigate project risks delivery conflicts


UK-Based Defence Contractor

The project responsibilities:-


UK-Based Defence Contractor

The project responsibilities:-

To provide Manufacturing Engineering and Technical support to Manufacturing Process areas and Project management a team of 32. Reviewing, auditing and approving of manufacturing and process documentation as the duly authorized SQEP person. The main purpose of the role is to lead Process design, development and introduction of best manufacturing practice in terms of productivity, reliability innovation and quality to the workplace, also to lead complex problem resolution of manufacturing problems designing processes into the new facility build program.


UK-Based Aerospace Engine Manufacturer

The project responsibilities:-


Aero-structures

The project responsibilities:-

To manage a research project into state of the art and future manufacturing and assembly process technologies for the next generation composite wing manufacturing. The work package is to provide:


Composite Armour

The project responsibilities:-

The client manufactures advanced composite components, integrates hardware and composite armour into military vehicles.

The role is to support the chief engineer with gaining acceptance from the MOD customer that the vehicles conform to the customer specification and that concessions raised are closed and properly integrated into the issues 1 design drawing pack. Part of the role is to project manage the mod kit retro fitting process to ensure that all of the vehicles are configured and conform to the base line design.


Aircraft Manufacturer

The project responsibilities:-

Provide manufacturing and support capabilities to a number of internationally important aircraft programmes including Eurofighter Typhoon and JSF F35-Lightning II. The assignment was to develop existing hard metal machining and assembly processes for the new JSF production facility at Samlesbury. Working with the NPI and the new factory layout teams the role included Specifying material, tooling requirements, procurement of new machine tools and metrology equipment, develop best practice when introducing existing manufacturing techniques to the new facility. On an ongoing bias on mature products, run shop floor level activities aimed at reducing product costs and increase quality on composite assemblies, advanced machined components, fabrication and advanced tooling manufacture. On existing processes carry out variation reduction activities to reduce recurring cost of the value adding manufacturing processes.Development of advanced manufacturing metrology techniques for a new state of the art machine shop leading to reduced inspection.


US Defense Contractor

The project responsibilities:-

Design and manufacture of special purpose military vehicles and carrying out safety case analysis on weapons Systems for the UK MOD. The role was to act as design authority supporting the chief Engineer on a major defense contract. Which included making decisions on design changes, reviewing and analyzing safety case data, product design for compliance with engineering drawings, working with the shop floor technicians to discuss and overcome and technical issues with the design, company standards and customer contract requirements. Also working as part of the HAZOPS (Hazard and Operability Studies) team evaluating a new battlefield data management system. Which involved taking a full description of the process and systematically questioning every part of it to establish how deviations from the design intent can arise once identified, an assessment is made as to whether such deviations and their consequences can have a negative effect upon the safe and efficient operation of the system. If considered necessary, action is then taken to remedy the situation to the satisfaction of the MOD Customer.

My main achievements were: To resolve design issues, raise concessions and process them quickly to allow the customer to accept delivery on time and to budget.


Capability Acquisition Aerospace Engine Manufacturer

The project responsibilities:-

The role included working as part of a team NPI team to assess equipment requirements and lead projects to introduce technology into the manufacturing process. Involving tool design, process development and manufacturing equipment acquisition also part of my role was working on the Measurement Excellence programme for the company. This included Inspection planning, Introduce Standard features and programming strategies. Reliance on post process inspection reduced through improved pre process and in-cycle measurement techniques

Fultec Engineering's main achievements were:

To develop an automated laser welding solution, investigate the feasibility of introducing laser welding and automated assembly into a pre-production development cell, involving tool design, process development and equipment acquisition.


Assist US company to set up in the UK-Relocation Project

The project responsibilities:-

To relocate a US based company who specialize in rapid injection molding, short run injection molded, using aluminum tooling and unique online design software. The scope of the project was to identify suitable UK factory site, work with the regional development agencies to secure funding. Procure all the equipment required, project manage the set up of the factory and hand over the factory to the management team.


Department of Trade and Industry

Interim - Process Improvement project

A DTI (Department of Trade and Industry) funded initiative that delivered the cross sector programme with NPL (National Physical Laboratory) to SME companies. The programme demonstrated the practical benefits of improving process and production capability within a variety of manufacturing sectors across the UK.

Main achievements:


Heinz Chilled Foods Luton: - Factory Relocation


Medical Device Manufacturer

Improve the manufacture of diamond machined Contact Lens and optics for UK and export markets.

Main achievements were:


Japanese electronic company

Manufacturing Engineering

To develop processes for a Japanese company, which manufactures printed circuit boards for television and video recorders, computers hardware, automotive ECU modules, air conditioning control switch modules and switch gear. The company operates a just in time, Kanban and kaizen system of work. My role here was to manage 16 production line on a 12hr continental shift this included taking fully responsibility for quality, product output, managing and developing 250 manufacturing and engineering staff , planning production, and making autonomous manufacturing and process / equipment decisions.

Main Achievements