- IOSH Affiliate Member
- Professional member of the Welding Institute (TWI)
PRODUCTION IMPROVEMENT MANAGER – ACCESS XL
Access XL is part of an international company, XL Group. Access XL specialises in the design and manufacture of hydraulic lifts such as moving decks, tail, wheelchair and mezzanine lifts.
Main duties included:
- Implementation of Continuous Improvement Processes and Lean Manufacturing Principles to improve efficiency, productivity, quality, staff competence and reduce waste.
- Review standard operating procedures for each activity within production for general manufacturing practices, quality control, and factory production control and health and safety requirements to ensure compliance with internal and external legislation.
- Implemented and maintained the Integrated Management System which included Quality ISO 9001 & Health & Safety Management ISO 45001
- Implemented Occupational Health Surveillance for the organisation
- Completed internal audits for Quality & Health & Safety
- Liaised with external accreditation bodies NQA, VOSA & Lloyds
- Performed COSHH & Risk Assessments
- Developed and introduced a welding quality manual and relevant procedures for the implementation BS EN 1090, BS EN 3834.
- Visual and Non-Destructive Testing of welds.
- Managed, trained and arranged welder qualification involving third party inspectors.
- Perform staff appraisals, setting out personal action, training and development plans to enhance contribution to the company.
- Introduction a training matrix and new procedures.
- Implemented a preventative maintenance plan and procedures for all machinery
- Organise and check the calibration of manufacturing equipment and ensure fit for purpose, creating a new calibration register.
- Managed Health and Safety awareness throughout all sections, via regular training, toolbox talks and unscheduled spot checks.
- Reviewed design team procedures to streamline the approval process.
WORKS MANAGER/RWC – GS ROBERTSON
GS Robertson offer a wide range of bespoke steel construction services including steel-framed buildings, fire escapes, staircases, balconies and architectural steelwork.
In this role I was responsible for allocating and organising the workloads of all production staff welders, fabricators and assemblers as well as liaising with design, purchasing, quality control and accounts staff. I had to set daily, weekly and monthly production plans/schedules outlining the targets to be met, allocating the required staffing and manufacturing equipment necessary to complete the task. I performed staff appraisals, setting out personal action, training and development plans.
I had to organise and check the calibration of manufacturing equipment to ensure it was fit for purpose and I was first port of call for reactive repairs and troubleshooting on all equipment. I implemented preventative maintenance plans and procedures for all machinery reducing downtime caused through breakdowns.
I was responsible for the Quality Management System and Health and Safety. I implemented COSHH working practices by generating up to date COSHH assessments and ensuring goods were stored appropriately. Health and Safety awareness throughout all sections of the workforce was promoted through regular training, toolbox talks and unscheduled spot checks. I had to review existing, and introduce additional, standard operating procedures for activities within the production area to reduce manufacturing times and ensure compliance with health and safety legislation. I ensured all work was carried out in accordance with ISO 9001, BS EN 1090, BS EN 3834 and with the Health & Safety policies, integrating a new management system for ISO 9001 in line with updated standard (2017 version).
As RWC I achieved accreditation to BS EN 1090 & BS EN 3834 by writing a Welding Quality Manual to add to existing ISO 9001 documentation. I was also responsible for carrying out visual and NDT inspections of welded components, documenting the results, approving and auditing external contractors, as well as developing welding procedures to ensure that all welding personnel were qualified to the appropriate level.
WORKS MANAGER/RWC – RAMSAY ACCESS
This role took my duties as Fabricator Welder and expanded them to give me responsibility for the overall management of the manufacturing production and the workforce within the company. I was responsible for staff appraisals, training and development. The staff included skilled tradesmen, installation technicians, apprentices and labourers.
During the initial period in this role, I negotiated with suppliers to reduce costs by 15%. A major part of duties was liaising and supporting customers regarding welding and engineering enquiries and requests as well as collaborating with the transport manager and customers to coordinate UK wide deliveries. I also tendered for various projects and carried out research and development work on new products.
Estimates and quotations became an integrated duty of this role. For larger projects with customers such as Babcock, MOD, Bilfinger Berger (Edinburgh Trams), Virgin trains, Scottish Water and Diageo I used principals of project management to ensure a smooth transition through the various project stages. The projects covered a variety of bespoke products to meet the customer’s specifications in line with international and legislative standards. The products were tailor-made to suit these requirements and included maintenance platforms, walkways, fixed and mobile platforms, stairs, ladders and handrails. This was a new concept within the company and required detailed planning and implementation to embed into working practices.
As Responsible Welding Coordinator, I wrote the welding quality manual and relevant procedures for the implementation BS EN 1090, BS EN 3834 and ISO 9001. Other duties within this remit included visual and non-destructive testing of welds.
In this position, I used a variety of Microsoft programs including Word, Excel and Access to develop templates and documents to assist me as well as bespoke software ‘exchequer’ which covered a variety of management applications i.e. stock, finance and procurement.
FABRICATOR WELDER – RAMSAY ACCESS
My duties were to interpret engineering drawings in various formats, AutoCAD, hand-drawn or architectural to fabricate and weld several components to assemble access platforms, gantries, fire escapes, stairs, ladders and handrails etc from materials such as steel, stainless steel and aluminium.
During this time, I was heavily involved in projects such as bespoke handrails for Terminal 5 at Heathrow Airport. I was consulted with regards to the design of the welded joints and materials through to making prototypes at the design stage to full completion of the handrails which are visible on top of the building.
I also trained and mentored numerous apprentices as a ‘journeyman’ in this position, along with training new starts. Most of these apprentices form the core of the current workforce as I and others in the company worked to develop a trainee programme that resulted in the majority of them being kept on at the end of their apprenticeship.
APPRENTICE FABRICATOR WELDER – RAMSAY ACCESS
After leaving school at 16 I was given the opportunity to become an apprentice fabricator welder at Ramsay and Sons. During this time I attended Angus Training Group for 9 months learning core engineering practices. After this period I worked under a skilled tradesman at Ramsay and Sons and studied at Angus College to gain my NC in fabrication and welding obtaining student of the year. At the end of my apprenticeship, I was given the opportunity to continue to study at night classes where I achieved a merit pass in HNC fabrication and welding.
One of my first priorities as Production Improvement Manager at Access XL I devised and implemented a welding quality system in accordance with ISO 3834 which included introducing new procedures and registers to ensure accreditation to the Vehicle Certification Agency.
In my position of Works Manager at GS Robertson, I redeveloped the workshop to make the layout more efficient and ergonomic, introducing a new preventative maintenance program to reduce downtime through breakdowns. I updated the Health & Safety policy along with generating new COSHH assessments to meet current legislation. I also updated the ISO 9001 Quality Manual to the 2015 version as well as updating the Welding Quality Manual to ensure the requirements of the company were met as effectively as possible.
During my time at Ramsay & Son (Forfar) Ltd I led the work to seek accreditation to BSEN 1090 (Part 1, 2 & 3). This is a European Construction Products Directive, to harmonise the safety performance during manufacturing. I undertook the role as Responsible Welding Co-ordinator (RWC), leading the implementation and enforcement through the introduction of a factory production plan and the BS3834 system principles into the workshop. This ensured compliance to the new EU legislation for all processes. We achieved accreditation at the 1st submission.
One of my initial duties when I took the role as Work Manager at Ramsay Access was to introduce a robust procedure to improve production times and streamline associated tasks. This started from reworking staff training records and production methods, through to risk assessments and production procedures. It ensured a more efficient and problem-free workshop facility, meeting targets and both managements and customers’ expectations.
The above enhancements assisted in the reduction of accidents in the workshop and cut the period of time when there were no recorded shop floor accidents down to nine months. I am now striving to improve this and have set a 12-month target.
A vast project at Terminal 5 at Heathrow Airport was the fabrication of bespoke roof handrails. I worked with the architects on the prototypes, giving my expert advice on how these could be manufactured as they had no welding knowledge and this was a new concept. After the creation of the prototypes, I then took the project to testing and production stage and then rolled out across the whole terminal.