General Manager @ From January 2014 to Present (2 years) Operations Manager @ Rationalised and simplified the collection of Operational Data covering all aspects of People, Labour and Material performance.
Used the data, together with hands on knowledge of the factory, to identify significant operational improvement. Incredibly committed to rapid change and prepared to work all hours on the factory floor with the Operators to understand processes, demonstrate the need for change and support factory teams.
Implemented live control measures to ensure that the new processes are being followed and delivering as expected. Failures are documented and discussed along with successes in structured weekly review meetings where direct reports are supported to deliver across a broad range of activities including Safety, Quality, Deliver, Cost and Morale
A naturally inquisitive person, with a keen attention to detail and logical thought process. I have gained a broad understanding of other functions including the Finance (P&L / Operational Accounts), Planning Systems and Technical Standards. From November 2011 to Present (4 years 2 months) Factory Manager @ From November 2010 to October 2012 (2 years) Manufacturing Improvement Manager @ Profit Improvement Plan
• Undertook comprehensive Site Opportunity Analysis identifying £x savings
• Worked with Factory Team to identify specific actions and regular audits to track delivery and ensure sustainability
Line OEE improvements
• Delivered significant Labour Savings and additional sales opportunity by Improving OEE on a key production line
Material Variance Report
• Designed and implemented “live” material variance report, reconciling to weekly General Ledger, enabling losses to be understood and live action taken
• Used data to significnatly improve Operational Variances From November 2008 to November 2010 (2 years 1 month) Shift Operations Manager @ Promoted to Shift Operations Manager, responsible for Goods In, Bakery, Assembly, Despatch and Outbound Logistics through a team of 15 managers and 250 staff. From March 2008 to November 2008 (9 months) Manufacturing Improvement Manager @ Delivered significant Operational Savings and Management Process Improvements across four sites within the UK & Belgium
Measurement, Management & Control
* setup and implemented a system for measuring and trending Operational Performance for OEE and Labour Efficiency
Operational Improvement - Labour
Delivered £1.2m of annualised savings through
* Value Added Time Studies & Line Balancing
* Effective Labour Planning / Control
Operational Improvement - Materials
Delivered £250k of annualised savings through
* 25% reduction in WIP Waste
* Reduction in Giveaway from 4.5% to 2.5% utilising Statistical Process Capability Studies to set product specific target weights
Planning
* understanding and implementation of Preactor and recipe generation tools into Production Areas From January 2006 to March 2008 (2 years 3 months) Production Manager @ Production Manager operating within a new flat management structure with 50 direct reports across four production lines, manufacturing over 100 products for both Thornton’s own retail portfolio and major retail multiples.
Key Achievements
KPIs
• Saved £75k on direct labour
• Trebled the output and halved the staff on a high volume Continental chocolate by modifying the production process saving £100,000/annum.
Teams
Self Management
• Developed self managed, empowered teams
Training and Development
• Introduced training programs aligned to individual Personal Development Plans
5S’s
• Implemented 5S’s to accelerate the development of a culture of teamwork and raise standards in both quality and H&S
Business Impact
• Successfully brought over 50 new chocolates from marketing concept to full production including challenging chocolate boxes for Thornton’s and Marks and Spencer
Capital Projects
• Led a team which designed, commissioned and installed a new £17k new chocolate application machine in under eight weeks ready for Thornton’s first product launch to the large retail multiples
• Identified, and led, through risk assessment a number of health and safety projects requiring £86k capital investment From May 2003 to January 2006 (2 years 9 months) Graduate Trainee Production Manager @ Joined the Greggs Graduate Scheme specialising in production management. Worked across three sites in a variety of developmental roles before being appointed Shift Production Manager. Responsible for production across all departments including Savouries, Soft Ferments, Bread and Confectionary through a team of four supervisors and 100 staff. From August 2001 to May 2003 (1 year 10 months)
Bachelor of Applied Science (BASc), Chemistry @ Durham University From 1997 to 2000 Andy Mayer is skilled in: Food Manufacturing, Food Industry, HACCP, Food Safety, Food Processing, Food, FMCG, Continuous Improvement, BRC, Bakery, Lean Manufacturing, Manufacturing, Food Science, Supply Chain, Production Planning