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Management Consultant

Work Experience

Consultancy Skills, Experience and Results
Analysis Skills - Very experienced process analyst, having completed over 20 analyses in the last five years.
·Consultancy team analyses for Blue Chip clients using and presenting techniques such as brown papers and ‘day in the life’.
·Extensive use of brown papers in the SME sector on sole-consultant analyses, leading to numerous project sales.
·Sectors experienced include retail, engineering, service, food, utilities, education, distribution and manufacturing.

Culture Change – Major change and improvements at a traditional textile company employing over 600 people.
·Working with the management & supervisory team (21 people), installed KPIs, weekly performance improvement meetings, improvement tools & techniques training sessions and specific improvement interventions.
·Reducing waste by 20% and increased efficiencies gave savings of £320k p.a., very significant in low margin business.
·MD stated that recent merger ‘would not have been possible without the work done by Marcus’.
·Training and development of workforce featured in BBCs ‘Working Lunch’ special on the textile industry, Dec. 1999.

Rapid Change - Major project at Kenwood Appliances aimed at rapid cost reduction and move to customisation strategy.
·Worked in motor winding & assembly, PCB assembly, water filter packing & assembly, and accessory departments.
·Conducted brown paper analyses, installed production & quality KPIs, trained management & supervision in pro-active management techniques, problem solving and financial reporting.
·Reduced labour costs by £150k and WIP by £30k in 6 weeks.
·Summer production peak completed without temporary labour when more than 150 normally used.

Service Tendering - Redefined distribution requirement for Printing.com.
·Involved all staff that interface with the distribution process. Developed new process that placed full control of delivery details with the stores using the IT network, including ability to make changes just minutes before jobs are dispatched.
·Invited tenders for distribution, with only three companies meeting the provisional requirements. Successful distribution provider (TNT) state that process is ‘unique in the country’ because of the level of integration into company processes and IT system. Off site consolidation and multiple pick-ups have reduced distribution costs while increasing production space.
·Store staff now have more time to add value, while providing enhanced customer service.
·Improved process has allowed despatch volumes to double without need to increase staffing levels.

Strategy Planning & Implementation - Developed, planned and implemented new strategy in ‘World Class Manufacturing’ project with corporate-wear clothing manufacturer.
·Strategy sessions identified need of existing customers for increased product range and quicker turnaround of smaller orders. Chose not to compete with high volume foreign imports or to expand customer base.
·Key action was to set up multi-skilled teams to specialise in short lead times and new product areas.
·Teams reduced typical lead times from 10 days to less than one day.
·Success of strategy required 10% increase in workforce to cope with extra demand.

Production & Capacity Planning - Supplier of stir-fry vegetables to supermarkets.
·Identified major weaknesses in production and supply chain planning leading to excess labour costs (overtime and temporary labour) and excess waste (poor volume guesses when committing to seven-day bean-sprout growing cycle).
·Developed 7 day, 24 hour capacity planning, trained staff in use of historical sales figures and weekly / monthly forecasts and measurement of planning accuracy.
·Reduced waste by 20% and labour costs by 25%. These figures were greater reductions than thought possible by the MD.


BPR / IT System Definition - Importer and nation-wide distributor of wooden furniture and paneling.
·Working with the senior management team, defined and critiqued the existing processes.
·All processes re-defined, from forecasting and purchasing, through sales order processing to dispatch and transport.
·Produced detailed ITT document and managed system selection process.

Line Efficiency - Identified weaknesses in line management and efficiencies at Motorola mobile phone assembly plant. Installed new measures that enabled team leaders to identify line bottlenecks more accurately so that maintenance interventions were more successful. Line efficiencies increased by 10%.

Management Team Development - Delivered training and implemented systems for team briefings, employee appraisals and management team meetings at bespoke envelope manufacturer. Priority was to improve On Time Delivery, which required all departments to improve and work together more effectively. By developing and implementing an agreed action plan in all departments productivity rose by 10% and On Time Delivery improved from 75% to 95% in six months.

Order Fulfilment - Developed PC based stock management system for supplier of timber products to trade and major DIY chains. System enabled stock replenishment to be planned more efficiently, giving lower stock levels and 100% next day delivery demanded by major customers. Improvements lead to company achieving ‘Top 10’ supplier rating for the first time.

Preventive Maintenance - Installed PM system for 80 presses at supplier to cosmetics and pharmaceutical industry. Major lubrication contamination problem discovered within weeks. Machine efficiency rose by 10% in 3 months.

LINE MANAGEMENT ROLES

Interim Operations Manager, Printing.com - Recruited to enable rapid growth following share flotation on the OFEX exchange by developing company processes and ensuring customer service levels were maintained.
·Ran centralised production unit with 30 reports over three shifts. Installed £1.5M investment in prepress, press and print finishing equipment within a 12 month period.
·Developed production planning and allocation process resulting in On Time Delivery increasing from 90% to 99% and Gross Margin increase by 10%. Enabled weekly output growth of over 100% in less than 12 months with no additional production head count.
·Developed end-to-end, customer facing, procedures such as ‘Design for Print’ documentation in order to clarify file and print specifications for all products and print processes. Reduced design & file supply errors and increased right first time order fulfilment from 90 to 98%.
·Heavily revised functionality of IT system. Produced detailed specifications for programmer to improve job tracking and cost visibility, developed the on-line quality system and reduced sales order processing errors. Resulting efficiency improvements were a significant factor in achieving results listed above.

Production Manager, Courtaulds Textiles (UK) - Responsible for 5 processes, 40 people, safety, quality & £100k consumable spend. Installed £1m fabric processing machine, multi-skilling, pay for skills, team working and revised department layout. High value lace production doubled in 6 months. Reversed £200k loss to £200k profit in 2 years.

Industrial Engineer, Courtaulds Textiles (USA) - Identified over $10m savings in activity sampling project in USA. All savings implemented within 2 years. Improved efficiency by up to 25% and quality by 75% in many departments by installing measured standards, quicker changeovers, performance reporting and Statistical Process Control. Led many improvement initiatives in successful Sarah Lee vendor certification programme. Letter of commendation sent by Vice President of Fabric Division to UK upon completion of placement.

Education

1990 MSc Ergonomics, Birmingham University
1989 BA(Hons) Industrial Design, Newcastle Polytechnic (Distinction for dissertation)

Skills

Business process re-engineering, product and process tendering, IT implementation, change management, process improvement, production planning, JIT, Kanbans and familiarity with most world class manufacturing techniques.

Languages

English only

Other

Excellent IT skills including Excel, Powerpoint, Internet
Current availability is immediate and is kept up to date on my web site.
I am self employed, live near Manchester, UK and travel is no object. I charge £350 per day plus expenses, but will negotiate lower rates for long term assignments.

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