Fast Moving Consumer Goods Companies

Multinational Change Management, Business Process
Re-engineering.

Assisted client program in Turkey that included the design plus implementation of upgraded and new operating and business systems and procedures and management practices.

This resulted in measurable improvements in the areas of indirect and overhead cost, direct unit cost, supply chain cycle time, operating margins, cost of quality, customer service, sales and pre tax operating profits of £20m GBP.

Installation of Bleach Manufacturing Facility.

Took full control and responsibility of the design, procurement, installation, training, commissioning and post commission optimization of a liquid bleach operation in Eastern Europe for regional sourcing.

This included all facets of the operation from bottle development and design, harmonization of products across multi-lingual borders and raw material sourcing.

Project completed in less than nine months, a company record. The design included advanced manufacturing techniques such as SMED (Zepf change parts were used throughout) and as a result the final product become the top performing operation of its type in the world, both in terms of the narrow factory operation and the supply chain opportunities the flexible low cost operation provided.

Upgrade of Liquid Detergents Facility.

Took full control and responsibility of the brownfield upgrading of an existing detergents liquids manufacturing operation.

This took the plant to fully hygienic best of class design complete with automated control and CIP systems in Eastern Europe for regional sourcing capability, further reducing its already competitive cost base.

Sourcing Project & onsite Vertical Integration of Bottle Supplier with Bleach Facility.

Conceived and developed a plan to integrate 3rd party supplier equipment and expertise managed by inhouse resource for the supply of bottles to inline feed them "freshly" directly to the bleach plant.

Following approval of the plan coordinated the total Project through to commissioning and handover. This was a first of its class type of Project for the client and has made the bleach operation the best of its kind in the world.

Multi million dollar savings resulted and the operation became leaner and more flexible as it was no longer reliant on supplier schedules and did not have to store vast quantities of packaging materials in order to meet the often varying customer demands.

Expansion and upgrade of detergent powders facility

Project Engineer for the upgrade of a detergent powder facility to triple its production output, automate its controls and improve its product quality whilst keeping its low cost manufacturing structure.

The project was initiated by the closure of a plant in Australia with the production being transferred to New Zealand. A massive project developed that required cross Tasman product and packaging harmonisation.

This was also made more difficult to ensure products met the stringent trans Tasman trade regulations. Due to the nature of the project was involved in every facet of the Project including many ground breaking designs and features, especially with respect to its powder handling capabilities.

The design was done on a 24 hr basis between the UK and New Zealand, resulting in a very fast design process. The Project itself was also the first of its kind for the company as it run with an international team cross continents team. Today the plant is amongst the highest performing in the world.

Design of innovative flexible powder handling facility

Initiated a completely new concept and design for a post blow dried powder handling and dosing facility. The result today is the most flexible handling and processing plant within the companies factories in the world.

The design allowed for the capability of production run lengths to be reduced from 50 to under 1 ton, with no significant changeover time between each run.

This has resulted in millions of dollars of savings across two countries due to more responsive demand fulfilment and reduced inventories. Waste and maintenance was also significantly reduced due to the simplicity and closed circuit of the design.

Implementation of site environmental control and containment system

Project Managed the implementation of a phased site containment system to ensure that potential environmental discharges of harmful and unfriendly products was all but eliminated in the event of an accidental spillage or an site disaster such as a 12 hour fire fight, or flood.