A committed and successful consulting professional, who has been influential in the development of operational excellence, in a variety of industries. A versatile and intelligent character, with the proven skills to drive performance improvements and deliver change in manufacturing and non-manufacturing businesses. A committed and capable practitioner of Lean techniques (VSM, OEE, 5S, TPM) and a certified Kata Coach, with the skills and experience to drive the People-centred philosophy through excellent understanding of leadership behaviours and change management.
Consulting Experience
Over 15 years experience working nationally and internationally with organisations, across many business sectors, including Financial Services, Healthcare, Food & Beverage, Aerospace, Automotive, Printing and Construction. Experienced at designing and delivering Improvement programmes for major, multi-site Customers. Qualified to highest level (3b) in Lean Competency System (LCS), showing demonstrated capability to develop and deliver lean programmes across extended Value Streams
Management Experience
2 years as Group Leader, Toyota Motor Manufacturing. Responsible for the day-to-day management of the Internal Logistics Department in Weld Shop. I led a team of 25, including 5 Team Leaders. Trained in all aspects of Toyota Production System. 10+ years in Production / Operations Management Senior positions within various manufacturing sectors. Including Food, FMCG, Construction Materials, Bathroom Systems.
Top 4 Headline Consulting Results
Led a two-year VSM driven transformation project at a major Food manufacturer that has resulted in over £2.1 million improvement in site profitability. Developed lean transformation model based on this which was rolled-out to 15 sites in UK and Ireland. Reduced ‘failure demand’ in a leading Bank’s PPI operations by 27%, by focused Root Cause Analysis and Kaizen-blitz activities with local work Improved productivity by 100% by leading a team through a series of Cellular Manufacturing workshops, including elements of Line Balancing & SMED in the Printing industry. Designed and implemented a Lean Maturity Programme in a major Credit Card provider, including coaching of Director of Operational Excellence
People Development
Certified Kata Coach with experience training and coaching teams in Toyota Kata and Scientific Thinking approach. Co-developed UK’s leading online Kata Coach training programme. Worked with senior clinicians and support staff to redesign a Non-Emergency patient pathway in a hospital which now is in Top 10 UK Hospitals for waiting times. Coached and mentored internal Lean Champions and team members in development of A3 Problem-solving at Management Services provider. Designed and successfully ran a Lean Champion Training programme for Lean Co-ordinators in a major Acute NHS Trust

At PJR Lean Associates (Lean Consultancy Staffordshire), we believe that every organisation has the power to transform and grow through strategic lean practices. With a unique blend of expertise and experience, PJR Lean Associates bring a wealth of knowledge in operations and lean deployment, taking a holistic approach to tackling complex challenges.
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