Expert Details

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

Expert ID: 728083 South Africa

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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.


Description of Actual Services Provided by Expert. 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 assessment

The situation has been and will be regularly re-assessed at +- 3 months intervals
Description of Actual Services Provided by Expert. 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 assessment

The 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)

Education

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

Work History

Years Employer Title Department Responsibilities
Years: 1981 to Present Employer: Undisclosed Title: Industrial Consultant Department: Responsibilities:
Years: 1979 to 1981 Employer: JACK MADER - Harrismith - and IMPREFED CONSTRUCTION - Johannesburg (South Africa) Title: Project Engineer and Plant Engineer Department: Responsibilities:
Years: 1974 to 1979 Employer: SPIE BATIGNOLLES Title: Plant Engineer and Project Engineer Department: Several Construction Sites in South Africa Responsibilities:
Years: 1972 to 1974 Employer: Self-employed Title: Industrial Consulting Engineer Department: Responsibilities:
Years: 1971 to 1972 Employer: AE&CI Ltd (African Explosives & Chemical Industries Ltd) Title: Plant Engineer Department: Responsibilities:

Government Experience

Years Agency Role Description
Years: 2000 to 2007 Agency: Cyprus Chamber of Commerce and Industry + Human Resources Development Authority of Cyprus Role: Conductor of "Vital Importance" programs in Cyprus Description: 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.

International Experience

Years Country / Region Summary
Years: to Present Country / Region: Summary: Please note 4 out of the previous 5 consulting examples were out of South Africa

Language Skills

Language Proficiency
Italian Mother tongue
English Excellent
French Medium

Fields of Expertise

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