Designed and delivered Lean Workshop appropriate to the insurance and services industry, incorporating real operational issues and developing practical improvement initiatives.
	Conducted detailed ‘lean’ assessment of the manufacturing facility to identify improvement projects for increased product throughput & reduced costs.
	Reduced end-to-end business process cycle time and labour input using DMAIC methodology.   Designed & implemented Key Performance Indicator (KPI) Metrics Dashboard and Scorecard System for running department business.
	Installation & operational sign-off of automated, high value manufacturing equipment.   Introduction of electronic system for performing predictive & preventative maintenance activities.    Installation of automated waste management system.       Analysis of manufacturing operations to identify opportunities for productivity improvement.   Reduced product changeover times yielding 5% uptime improvement across all manufacturing lines.   Re-layout of manufacturing line to reduce space by 30% & facilitate product flow without wait times.
	Design & installation of warehouse facility for: Handling & storage of inbound raw materials. Kitting & delivery of raw materials to production. Packing, consolidation & shipping of finished product.
	Design & implementation of new process to reduce product leadtime (order-to-ship) from 72 to 24 hours, resulting in improved strong customer retention & customer satisfaction.
	Conversion of ungraded area into cleanroom grade 2 manufacturing area.   Procurement, installation & utility hook-up of manufacturing & support equipment.   Room & equipment commissioned & handed over to operations on schedule & within budget.
	Installation of automated flexible manufacturing system to replace manual lines delivering substantial productivity & cost improvements.