Expert Details

Glass Container Production

ID: 737287 United Kingdom

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Expert has been in Glass Container Operations all of his working life. Now semi-retired and acting as a private consultant, he has recently been working on the design of a newly approved, UK grant-funded, Glass Pilot Plant.

He previously held various key roles at Ardagh (Glass) including Plant Manager, Operations Manager, Engineering Manager, Technical Director, and latterly European Operational Excellence Group (OEG) Roles.

In 2020, Expert finished working full-time with the Ardagh (EU) after more latterly working with the Operational Excellence Group (OEG) and with the 20 Ardagh plants in Europe establishing Best Practices in Glass Container Forming. Additionally working on continuous improvement methods to improve productivity and quality in the glass container forming process, applying a six-sigma approach wherever possible.

Together with the input from all Ardagh (EU) Glass Container Forming departments, he implemented and integrated an online glass container fault correction database to list standard defect causes and corrective actions (approximately 2,500 cause/action combinations registered). This is now used as a standard system in the Ardagh Production System and data is now being used to identify trends and improvement opportunities.

Other projects include production performance benchmarking approach development, simplifying six sigma for use at the hot end (now adopted by other departments), swabbing standardization (based on test-study results), mold-gear coatings testing and assessment, and leadership of various plant/line Production Performance Improvement projects as identified by Senior Management.

In the recent past, Expert won the Ardagh Global 'BSafe!' Award for Personal Contribution to Safety. This was for safety improvements made at the Hot End. Safety projects included reducing implementation of standard swabbing equipment and procedures to reduce swabbing injuries to zero over the previous 8 years in over 20 European plants; 26 Forming safety best practices established, and latterly the development of mechanical IS Machine section-safety devices which were in the plant-implementation phase as he left the company for retirement.

Available for glass container production consultancy roles, or short problem-specific consultation sessions.

Based on his experience outlined above, Expert is now offering to help a wide range of businesses and individuals connected with the glass container industry. This would include, but not be limited to:
- Glass container manufacturing plants with specific problems to solve, or which may benefit from general plant operational audits to identify possible improvement opportunities.
- Customers of glass plants with issues arising that cannot be readily resolved with the supplying glass plant, or who need proactive quality/operational audits to give assurance that there is no significant product quality risk from their chosen source of glass container supply.
- Complainants of faulty glass products that need Expert Witness input in order to resolve their cases.
- Developers of glass plant equipment who would benefit from glass-expert input at key stages of their product development cycle.
- Glass Plant Safety audits as this of increasing concern for what has traditionally been a challenging environment, especially in the 'hot end' of the process.

Education

Year Degree Subject Institution
Year: 1996 Degree: MSc Subject: Manufacturing & Management Institution: Sheffield University
Year: 1988 Degree: BEng Subject: Electronic Systems & Control Engineering Institution: Sheffield Hallam University

Work History

Years Employer Title Department
Years: 2020 to Present Employer: Undisclosed Title: Consultant Department:
Responsibilities:
Offering expert assistance to companies needing help with technical matters relating to glass container production or use of glass. A major on-going consultancy role is to be part of the technical team designing the Research & Development Pilot Plant in the UK.
Years Employer Title Department
Years: 2010 to 2020 Employer: Ardagh Glass Ltd. Title: Forming Best Practice Manager Department:
Responsibilities:
Establishing methods best practices and agreeing European Group improvement initiatives to be implemented in the hot end operations in European Plants. Holding workshops and conferences to discuss matters of substance and detail before voting on standard and best practices. Major initiatives led to daily acceptance of Lean Six Sigma approaches, improved safety, and implementation of a defect correction expert system used in all plants (believed most advanced of its time).
Years Employer Title Department
Years: 2009 to 2010 Employer: Ardagh Glass Ltd. Title: Finished Products Best Practice Manager Department:
Responsibilities:
Establishing methods best practices and agreeing European Group improvement initiatives to be implemented in the cold end operations in European Plants. Holding workshops and conferences to discuss matters of substance and detail before voting on standard and best practices.
Years Employer Title Department
Years: 2009 to 2010 Employer: Ardagh Glass Ltd. Title: Group Know How Co-ordinator Department:
Responsibilities:
Establishing methods to acquire and store manufacturing knowledge and best practices which were then rolled out across 20 European plants. System still in use to this present day and continually being updated by team members of the Operational Excellence Group.
Years Employer Title Department
Years: 2008 to 2009 Employer: Ardagh Glass Ltd. Title: UK Director of Technical Services Department:
Responsibilities:
Managing the Technical Centre for UK until UK unit was amalgamated with the European team into Central Technical Services. Planning furnace rebuilds and other major plant capital investment programmes. Participating in Senior Management meetings to co-ordinate daily work with company strategy and business direction.
Years Employer Title Department
Years: 2006 to 2008 Employer: Ardagh Glass Ltd. Title: Plant Director Department:
Responsibilities:
Responsible for the Knottingley Plant and its activities to meet customer requirements and achieve planned profit performances.
Years Employer Title Department
Years: 1999 to 2006 Employer: Rockware Glass Ltd. Title: Operations Manager Department:
Responsibilities:
Responsible for the day-to-day operation of the glass container manufacturing facility. Reporting direct to the Director of Operations with all production related departments reporting through Expert. Responsible for factory operational performance and success of internal continuous improvement initiatives.
Years Employer Title Department
Years: 1997 to 1999 Employer: Rockware Glass Ltd. Title: Assistant Production Manager Department:
Responsibilities:
Working on the production management team to improve productivity and quality.
Years Employer Title Department
Years: 1997 to 1998 Employer: Rockware Glass Ltd. Title: Engineering Manager Department:
Responsibilities:
For Plant Engineering function with team of 25 electrical and mechanical craftsmen and supervisors. Responsible for plant engineering services to the glass factory manufacturing process.
Years Employer Title Department
Years: 1990 to 1997 Employer: Rockware Glass Ltd. Title: Project Manager Department:
Responsibilities:
Working on specification and installation of major capital investment projects managing teams of contractors under CDM Regulations. Annual spend circa £10M.
Years Employer Title Department
Years: 1990 to 1984 Employer: Beatson Clark plc Title: Electronics Engineer Department: Production Engineering Development Department
Responsibilities:
Working on the selection, specification, installation, and maintenance of process control systems.
Years Employer Title Department
Years: 1988 to 1988 Employer: Redfearn Glass plc Title: Assistant Project Engineer Department:
Responsibilities:
Worked on applying computer Expert Systems to process control.
Years Employer Title Department
Years: 1985 to 1988 Employer: Redfearn Glass plc Title: Undergraduate vacation work Department:
Responsibilities:
Undergraduate vacation work and 15-month industrial placement
Worked on real-time process control software commissioning/debugging, fault-finding on process control hardware, and systems' documentation.
Years Employer Title Department
Years: 1981 to 1984 Employer: Redfearn Glass plc Title: Apprentice Department:
Responsibilities:
Served EITB electrical apprenticeship.

Career Accomplishments

Licenses / Certifications
Green Belt LSS
Chartered Engineer (CEng).
Level V NVQ Operations Management
In 1994 passed City & Guilds qualification in Communication of Technical Information (Parts 536O-1 & 536O-2) after studying by correspondence course.
Awards / Recognition
- Travel Award from Sheffield City Polytechnic and the Armourers' and Braisiers' Company, Sheffield.
- Master Cutler's prize for the best (year undisclosed) Travel Award Report.
- Won IEE Institution Prize
- Adagh Group Global BSafe Award in recognition of Personal Contribution to Health and Safety (Hot End Safety Improvements)

Publications and Patents Summary
Author of articles published in Glass International magazine

Additional Experience

Training / Seminars
EDUCATION
1975 - 198O Royston Comprehensive School:
GCE 'O' level English Language (C)
CSE - Maths (2) English Language (1) Physics (2)
Biology (2) French (4)
198O - 1984 Barnsley College of Technology:
B/TEC National Certificate in Electrical Engineering
with grades of 6 Distinctions, 8 Merits and 2 Passes.
1984 - 1988 Sheffield City Polytechnic:
Bachelor of Engineering (B.Eng.) First Class Honours
Degree in Electronic Systems and Control Engineering.
1994 – 1997 Sheffield University MSc Manufacturing Technology & Management (passed with Distinction).

Fields of Expertise

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