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 Expert  728083

Expert in Lean Manufacturing, Lean Project Management, Lean Maintenance/Plant Management


Available for your Consulting and Expert Witness Needs

South Africa
Education Work History Consulting Services Expert Witness

Summary of Expertise: Listed with other top experts in: 
Expert has over 29 years of specific experience (1981 to date) - Free-lance Project Engineer, Industrial Engineer, Project Manager and Professional Consultant - (South Africa - Lesotho - Swaziland - Zimbabwe - Botswana - Mauritius - Cape Verde - Brazil - Italy - Kenya - Lebanon - Malta - Romania - Croatia - Turkey - Cyprus - India - Malaysia - Namibia - Saudi Arabia). 3 main fields of activity: a) Project Engineering, Industrial Engineering and Project Management (4 years) on a free-lance/contract basis in various Construction/Installation and Industrial Engineering Projects on assignment by and in contact with large international Companies featuring high levels of know-how and organisational content (Siemens, Deutz, Caterpillar, Fluor, Karbochem, etc.). b) Industrial Engineering and Operations Management Consulting (25 years) - Sectors of activity: Productivity - Materials Management - Work Study - Layout Studies – Feasibility Studies - Cost Control Systems - Quality Control and Assurance - Total Quality Management - Lean Manufacturing - Total Productive Maintenance - Process Improvement, Management & Re-Engineering - etc. c) Management & Project Management Consulting and Human Resources Development (22 years): Training and Motivating Managers, Project Managers, Project Engineers, Middle-level Managers, Site Agents, Foremen, Supervisors, Workers, Administrative and Commercial Employees, etc. - Setting up Project Management and “Lean” Project Management structures in Project-driven Companies - Setting up Total Quality Systems - Setting up “Lean” processes and “Lean” practices in Manufacturing enterprises and Service Establishments - setting up TPM-based Maintenance structures in Manufacturing enterprises and Construction Companies.
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continuous flow manufacturing

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continuous process

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design process

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flexible manufacturing

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group technology

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industrial engineering

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industrial engineering setup time reduction

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job shop operations

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just-in-time inventory

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kanban

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lead time

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lean manufacturing

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line balancing

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manufacturing automation

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manufacturing cost control

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manufacturing facility design

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Methods-Time Management

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motivation

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plant management

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product variety optimization

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productivity improvement

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productivity measurement

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project management

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project planning

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project review

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project scheduling

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team building

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total productive maintenance

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total quality management

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work team

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world-class maintenance

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lean project management


Show Secondary and Basic Areas of Expertise

Often requested
with this expert:

Lean Manufacturing Engineering and Production Systems...
Market Trends, Lean Manufacturing, 5s, Six Sigma, One Box...
Materials and Manufacturing Management
Lean Manufacturing, Kanban

Education:
Year   Degree   Subject   Institution   Honors
1970   Doctor Degree   Electrical Engineering   Politecnico di MIlano   Honours

Work History:
Years   Employer   Department   Title  

1981 to

 

(Undisclosed)

 


 

Industrial Consultant

 

1979 to 1981

 

JACK MADER - Harrismith - and IMPREFED CONSTRUCTION - Johannesburg (South Africa)

 


 

Project Engineer and Plant Engineer

 

1974 to 1979

 

SPIE BATIGNOLLES

 

Several Construction Sites in South Africa

 

Plant Engineer and Project Engineer

 

1972 to 1974

 

(Undisclosed)

 


 

Industrial Consulting Engineer

 

1971 to 1972

 

AE&CI Ltd (African Explosives & Chemical Industries Ltd)

 


 

Plant Engineer

 

Government Experience:
Years   Agency   Role   Description
2000 to 2007   Cyprus Chamber of Commerce and Industry + Human Resources Development Authority of Cyprus   Conductor of "Vital Importance" programs in Cyprus   The HRDA of Cyprus (a Public Organisation) sponsors and finances a number of so-called Vital Importance programs addressed to enhancing local industry competitiveness. The programs are actually organised by semi-public Organisations (such as the Cyprus Chamber of Commerce and Industry – KEBE) and other private Organisations. Each programs consists of: ? An initial Training program (at least 2 days – max 5 days) with attendance limited to 25 enterprises An immediate 1-day follow-up consulting/coaching visit at each participating enterprise premises, targeting at assessing the current status-quo - initiating/launching competitiveness-enhancing programs – consulting/coaching/recommending – reporting to the HRDA Private, subsequent follow-up of the implementation progresses (optional, at the discretion of the concerned enterprise

Expert has been selected to conduct over 20 Vital Importance Programs over 7 years, including, inter-alia, several World-Class Manufacturing, Lean Manufacturing, Total Employee Involvement in Manufacturing Operations and Total Productive Maintenance. The overall number of local enterprises assisted exceeds 150 (micro, small and medium Manufacturing Enterprises – all possible sectors: from electronics to cosmetics, sheet-metal working, furniture manufacturing, food and beverage, textile, fashion and garments, slaughter-houses, cement, electricity generation, marble and tiles, paints and chemical, pharmaceuticals, para-medical, etc.). Achievements: productivity improvements of up to 85% - quality defectiveness reduction up to “zero-defects” – throughput time reductions up to 80% - stock levels reductions up to 1/5 ECH.


Consulting Services:
Selected Consulting Examples:
  • Description of Actual Services Provided by Expert to a high-tech Company in South Africa:# Analysis of the current state in the Operations area (3 main value streams)# Analysis of the Organisational Strategies and Structure of the Company# Definition of an action (training + coaching) plan# Video-recording of positive and negative aspects of the current manufacturing operations style in the selected areas - highlighting wasteful aspects and areas needing lean improvement# 24 hrs. training on Lean Manufacturing, Lean Thinking, Lean Project Management and Lean Product Development techniques – sensitising key personnel on the need for “lean” by showing the video-recorded movie, thus generating high awareness# Drawing up a plan of action for the next 3 months with deep involvement of key-staff (launching a 5-S program - launching Value Stream Mapping activities for core processes –design of a “temporary” Kanban system in one of the operational areas – launching of Poka-Yoke initiatives in areas needing drastic quality improvements – launching of Lean Product Development/Lean Project Management initiatives in the concerned areas - etc.)# Setting-up significant Lean Indices (KPIs) to be monitored over time, for subsequent assessmentThe situation has been and will be regularly re-assessed at +- 3 months intervals
  • Description of Actual Services Provided by Expert to medium-size manufacturing enterprise (products: agricultural implements):# Analysis of the current state in the Operations area (2 factories, several value streams)# Analysis of the Organisational Strategies and Structure of the Company# Definition of an action (training + coaching) plan# Video-recording of positive and negative aspects of the current manufacturing operations style in the selected areas - highlighting wasteful aspects and areas needing lean improvement# 4 x 16 hrs. training on Lean Manufacturing and Lean Thinking techniques – sensitising key personnel on the need for “lean” by showing the video-recorded movie, thus generating high awareness# Drawing up a plan of action for the subsequent 3/6 months with deep involvement of key-staff (launching a 5-S program - launching Value Stream Mapping activities for core processes – launching cell and flow production initiatives in self-contained production areas - launching of Poka-Yoke initiatives in areas needing drastic quality improvements – etc.)# Setting-up significant Lean Indices (KPIs) to be monitored over time, for subsequent assessmentThe situation has been and is being regularly re-assessed at +- 6 months intervals
  • Introducing Lean Manufacturing and TPM principles in a large-size hi-tech continuous on-line Petro-Chemical Complex:# Analysis of the current state in the Operations area# Analysis of the Organisational Strategies and Structure of the Company# Definition of an action (training + coaching) plan# Video-recording of positive and negative aspects of the current manufacturing operations style in the selected areas - highlighting wasteful aspects and areas needing lean improvement# 48 hrs. training on Lean Manufacturing and TPM techniques – sensitising key personnel on the need for “lean” by showing the video-recorded movie, thus generating high awareness# Drawing up a plan of action for the future with deep involvement of key-staff (launching a 5-S program - launching TPM and Autonomous Maintenance activities for core processes/core lines – etc.)# Setting-up significant Lean and TPM Indices (KPIs) to be monitored over time, for subsequent assessment
  • Introducing and launching Lean Manufacturing Principles in a medium/large-size brewery:# Analysis of the current state in the Operations area# Analysis of the Organisational Strategies and Structure of the Company# Definition of an action (training + coaching) plan# Video-recording of positive and negative aspects of the current manufacturing operations style in the selected areas - highlighting wasteful aspects and areas needing lean improvement# Over 120 hrs. training on Lean Manufacturing, TPM, Quick Change-Over and 6 Sigma techniques – sensitising key personnel on the need for “lean” by showing the video-recorded movie, thus generating high awareness# Drawing up a plan of action for the future with deep involvement of key-staff (launching a 5-S program - launching TPM and Autonomous Maintenance activities for core processes/core lines – launching a Quick Change-Over program – Re-organising Layout for Continuous Flow - etc.)# Setting-up significant Lean and TPM Indices (KPIs) to be monitored over time, for subsequent assessment# Regular follow-up assessments/evaluations/coaching on a yearly basis.# Results achieved: OEE improvement by over 60% - Set-up reduction time over 60% - Throughput time reduction over 40% - Quality defectiveness reduction over 80%
  • Introducing and launching Lean Manufacturing Principles in a medium-size manufacturing enterprise:# Analysis of the current state in the Operations area# Analysis of the Organisational Strategies and Structure of the Company# Definition of an action (training + coaching) plan# Video-recording of positive and negative aspects of the current manufacturing operations style in the selected areas - highlighting wasteful aspects and areas needing lean improvement# 24 hrs. training on Lean Manufacturing and Quick Change-Over techniques – sensitising key personnel on the need for “lean” by showing the video-recorded movie, thus generating high awareness# Drawing up a plan of action for the future with deep involvement of key-staff (launching a 5-S program - launching flow-line/cell production programs in intensive-labour areas – launching a Quick Change-Over program – Re-organising Layout for Continuous Flow - etc.)# Setting-up significant Lean Indices (KPIs) to be monitored over time, for subsequent assessment# Regular follow-up assessments/evaluations/coaching on a yearly basis.Results achieved: Productivity Improvements up to 50% - Set-up reduction time over 60% - Throughput time reduction over 40% - Stock level reduction to 1/5 (documented in movie case study)
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
Lean Manufacturing: Productivity improvements: up to 120% Throughput Time Reduction: over 60% Stock/Inventory reduction: up to 1/5 Zero Defects

Lean Project Management: Lead time reduction: up to 50% Errors/defects/mistake reduction: very high

Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

International Experience:
Summary
Please note 4 out of the previous 5 consulting examples were out of South Africa

Language Skills:
Foreign Language   Description
Italian   Mother tongue
English   Excellent
French   Medium

 

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