Ian Buxton
Managing Director
B.Eng(Hons), Dipl. Ing (FH), MBB, MIoD,
Ian’s background is in engineering, starting with a career in Aerospace at Rolls-Royce IMGT working in Technical support and Control Systems. Ian was the focal point for ESPRC funded research with Oxford University into Novelty Detection. This led to the development of Neural Network based automatic pattern recognition for combustion system health monitoring and a paper published in the International Journal of Systems Science 2000 Volume 31, Number 11, Pages 1427-1439.
In 1998 he moved into Automotive with Jaguar Land Rover where he led integration of engine management systems components before training as a Black Belt.
Ian has over 15 years experience in process improvement and is a Lean Six Sigma Master Black Belt certified by Ford and Six Sigma Academy.
He thrives on new experiences, meeting new people and working with them to solve problems.
He has consulted in over 20 countries since 2004 enjoying the diversity of travel, different cultures and the ability to share his problem solving skills with a broad range of leaders and experts from different industries.
Ian lives in the Isle of Man with his wife and 2 sons, his interests outside work include technology, F1 and Beekeeping.
Industry Experience
Aerospace
Ian's career in Engineering began in Rolls-Royce Industrial and Marine Gas Turbines. He worked in Technical support for the RB211 fleet before joining the Control Systems team where he led the development of remote engine health monitoring. This facility was used for engineering support of the first production RB211-DLE operating in the Trans Canada gas pipeline. Recently he worked with Rolls-Royce to develop and deliver a bespoke coaching based training intervention for supplier quality assurance.Automotive
Ian worked with Jaguar cars in Electrical supporting OBD II diagnostics and engine management system development and integration. As PMST lead he led the electrical team in the development and validation of the EMS in conjunction with Powertrain and suppliers. Ian is certified as a Black Belt by Six Sigma Academy and Master Black Belt by Ford Motor Company. Since leaving JLR Ian has worked with automotive OEMs and suppliers to improve production quality.Finance and Insurance
Ian has supported financial processes in Oil and Gas, Banking and Information industries. Projects have included Sarbanes Oxley compliance, VAT reporting, recovery and error reduction. In a reinsurance company he supported the Lean analysis in a multi-location Mega-Kaizen that led to strategic reorganisation as well as local process improvements.Food Manufacturing
Ian has worked with a leading food manufacturer to train and coach MBBs and BBs in UK, Netherlands and Italy. In a separate Kaizen event with the food company and a key supplier he led the group to evaluate process steps and logistics from supplier production through to packaging setup including delivery, handling, booking in, warehousing, production readiness, defect reduction. Improvements were identified in cycle time, warehouse space and inventory reduction. Recommendations included elimination 95%+ of examined material in food manufacturer's warehouse and just in time delivery of production ready kit of materials for each week with no risk to production up time.Manufacturing
Ian has worked with several manufacturing clients including light assembly, heavy machinery and continuous processes. Most recently he worked in Switzerland to coach and guide Lean implementation in manufacturing assembly. Much of this work was conducted in German language both with executive teams and shop floor employees from Serbia, Italy, Brazil and Asia with German as a second language. He introduced cellular manufacturing layouts to increase production flexibility from 70 units per day to over 300. Gemba walks and meetings were used to break down barriers between departments and modify problem solving behaviours to support production. At a more strategic level, Ian worked with European executive team, HR and the German Sales team of another company to review their back office processes. The analysis led to recommendations to restructure the back office processes to increase efficiency and enable additional customer facing sales roles to be created. This was conducted with sensitivity to German employment laws and social plans.Petrochemical
Ian has worked extensively with Shell and others in the Oil industry in UK, Netherlands, Kuwait, Oman and Qatar. He has led training and coaching in Lean and Six Sigma in Europe, Asia, Middle East and USA for Upstream, Downstream, Trading and HR functions. Trusted advisor roles included the coordination of curriculum development, interviewing consultants and recruiting MBBs as well as chairing the Alliance on Consultants, a unique group collaboration of multiple consulting companies working to common standards in one company. Ian was the certification process owner from 2004-2014 ensuring standards of project delivery were adhered to.Pharmaceutical
Ian led MBB development and Black Belt coaching in a generic Pharmaceutical manufacturer in UK, Iceland and Denmark including projects in animal pharmaceuticals production. He also led Green Belt and Black Belt training and coaching for a research organisation focused on improving the efficiency in their GLP processes, QC and reporting.Previous Clients
- Actavis
- Alpharma
- Bosch Alternators
- Daimler
- Heinz
- Heimeier
- Ikon
- Jaguar Land Rover
- Kuwait Oil Company
- Kuwait Petroleum
- Petroleum Development Oman
- Rolls-Royce
- Schlumberger
- Shell
- Thomson Reuters
- Voith Paper Packaging
- Voith Turbo
Richard Redfern
Associate Director
B.Eng MBB
Richard has worked for a number of well respected global blue chip companies in FMCG and major projects.
Richard has been a certified Master Black Belt and principal trainer for a 40,000+ employee global blue chip company on their Lean Six Sigma change programme. He developed Lean Six Sigma training materials, processes and software to train companies around the world. He has developed material and examples which focus on the local business needs.
He has delivered his training across 4 continents and coordinated the translation of his material into many languages. He has trained more than 70 Black Belts (Experts), more than 60 Green Belts (Specialists) and hundres of Directors, Managers and Front line operators. The programmes realizing multi million pound/euro and dollar net savings.
Richard has worked on a Complex Change Programme with AT Kearney, where he mapped, analysed and improved Project Management techniques.
Richard has lead successful teams in Product Development, Order Processing, Production, Manufacturing, Tendering and Procurement.
Richard has carried out International Sales and Marketing around the Middle East Bahrain, Dubai, Saudi Arabia, Abu Dhabi, Qatar and Oman.
Core Skills:
· Certified Six Sigma Master Black Belt – deployment, training and practice of Business Improvement (Both Transactional and Manufacturing),
· Change Management. Team, Group and Meeting Facilitation.
· Lean, 5S, Kaizan
· Pan European Supply Chain – Joint Process Improvement
· Project Management, Earned Value Analysis, Risk Evaluation and Management.
· IT System development to support and enhance Business Processes.
· NLP, Jung, MTBI and Keirsey Personality Types, Belbin Team Roles, Honey Mumford Learning Styles.
Industry Experience
Agriculture
Distribution
Energy
Finance
Food Production
Power
Telecoms
Warehousing
Previous Clients
- H J Heinz Company Limited
- Six Sigma Academy
- British Telecom (BT)
- Strategic Business Partners
- Renault Nissan Institute
- Competitive Capabilities International
- VA TECH Transmission and Distribution
- Reyrolle Switchgear,Projects,Protection
- Peebles Transformers
- ASTA (Austria)
- Ferranti-Packard Transformers (Canada & Mexico)
- Jermont Schneider (Lyon)
- Schneider (Grenoble)
- Easun Reyrolle (India)
- Holec (Netherlands)
- ITNET
- Air Academy Associates
- Rolls-Royce Industrial Power Group
- Bushing Company
- Clarke Chapman Marine, Manufacturing & Engineering Services
- Cowans Boyd
- Stothert & Pitt
- Wellman Booth
- Syncrolift
- Belliss & Morcom
- Crossley Engines
- Valtek Engineering
- Rolls-Royce Industrial Controls
- NEI International (Sales & Marketing)
- Allen Diesel, Allen Gears
- International Research & Development (IRD)
- Baldwin & Francis
- Becorit
- Clayton Equipment
- DAC
- Victor Industrial Equipment
- Transtar
- Wultex
- International Combustion
- Cochran Boilers
- Parsons Turbine Generator Services and Thompson Nuclear Engineering
- Thompson Kennicott, Thompson Defence Projects
- Thompson Welding Systems, Thompson Horseley Bridge
- Sir William Arrol
- Thompson Tankers, Thompson Valves
- CHI Controls
- Nothern Engineering Industries (NEI)
- EDS
- AT Kearney
Mike Holman
Consultant
Mike has 20 years experience in Continuous improvement achieving Master Black belt certification with AlliedSignal Automotive division in 1996.
Since 2001, Mike has worked as a Lean Six Sigma consultant.
Throughout his career Mike has trained over 800 Black belt and Green Belts and provided coaching support to their Continuous Improvement projects.
Most recently, Mike has been supporting the Fuels Retail division of a Global Oil Company.
In this role, Mike has supported projects delivering approximately $30M of financial benefits.
Mobile: +44-7734-800224
Email: Mike@process42.com
Industry Experience
Automotive
Mike has supported many clients including major Alternator, Turbocharger and Spark Plug manufacturers, training and coaching over 100 Black Belts and Green belts. Project included improving turbocharger balance and reducing turbocharger noise, improving alternator efficiency and reducing scrap by 65%Energy
Mike has supported a major wind turbine manufacturer, training 40 Green belts and delivering Design for Six sigma training. Projects included improving turbine efficiency, resin bonding and machining.Electronics
Mike supported a major electronics manufacturer, training 40 Black Belts and 2 Master Black Belts. Projects included improving yield by 60% on a printed circuit board soldering process.Fast Moving Consumer Goods
Mike has supported several clients in the high speed manufacture of food and beverages. Projects included multi head filling machine diagnostics to ensure low variation in product weight. Customer complaints were reduced by 37%.IT
Mike has supported a major IT Company. Projects included reducing software design time by 30%.Manufacturing
Mike has supported many clients including major Paper, Automotive and Wind Turbine manufacturers, training and coaching over 100 Black Belts and Green belts. Project included improving turbocharger balance and reducing turbocharger noise, improving alternator efficiency and reducing scrap by 65%Nuclear
Mike has 6 year’s experience in the UK Nuclear Industry in Manufacturing and waste processing. Projects significantly contributed to safety and the environment.Oil and Gas / Petrochemical
Mike led the Black Belt curriculum design and delivery for a major petrochemical company. In this role he coordinated material development with other team leaders, led train the trainer and training delivery and managed delivery teams selected from both multiple consulting partners and internal resources. Mike currently leads the training and coaching for a team of 70 green and black belts across Europe. Working in a team with six other MBBs, Mike delivers support for Europe, USA and Asia MBB colleagues as well as programme management support for the Deployment lead as a trusted advisor. The programme has delivered $400M in bottom line benefits with Mike’s projects contributing $30MClient List
- Allied Signal
- BNFL
- Bosch Alternators
- Crown Cork & Seal
- Diageo
- EDS
- Flextronics
- Ford Motor Company
- Garrett
- Honeywell
- Ikea
- JCI
- Korsnas Packaging
- Pfizer
- Shell
- Siemens Wind Power
- SWM International
- Triplex
- Voith Filters
David Cowburn
Associate Director
B.Eng PhD DMS MBB
David has over twenty years’ experience implementing Lean and Six Sigma deployments and improvements in service, finance, administrative and manufacturing businesses with a demonstrable track record of delivering substantial benefits for domestic and international clients.
Able to train, facilitate and coach at all levels in an organisation from board level to front line staff in a people based hands-on style to implement transformational culture change and bring about rapid measurable step changes in performance to systems and processes.
Industry Experience
Aerospace
Led Lean deployment and trained internal Lean facilitators in waste identification, 5S, one-piece-flow, SMED and Poka Yoke as part of a CEO driven culture change initiative at a major German Aerospace seat manufacturer. Applied Lean principles to a global aerospace supply chain organisation, rationalising suppliers and supply chain processes improving delivered in full KPI from 65% to 98% and reducing purchase costs by 7%. Increased grinding output from 560,000 to 800,000 per week in an Aerospace component company, utilising Six Sigma methodology with £190,000 per annum saved and £1.3m cash released.Alternative Energy
Saved over €35m in product cost through 3P (Production Preparation Process) workshops for a global leader in “green” energy. Designed a dual product ‘pulse’ flow line for a major wind turbine manufacturer involving ‘live’ Kanban supply, sub-system build and cellular production double loop production layout.Automotive
Experience in; optimisation of forged truck axle beams for Volvo, Scania, Mack, Mercedes-Benz and Renault. Real-time data collection of car suspension components. Resolution of an Axel vibration problem for Jaguar cars. Development of GRP composite components for optimisation of weight. Running automotive tier one component businesses supplying, Ford, GM, JLR, Toyota, Nissan and Honda using cellular layouts, Lean processes to showcase levels. Reduced end of month management accounting processes from 18 to 11 days with plans in place to reduce further to 8 days with Korean automotive manufacturer with 17 subsidiary reporting units.Food Industry
Supported a factory wide 3 shift 5S improvement process within a milk bottling plant. Identified $50m of potential savings in an Australian Chicken processing chain.Healthcare
Coaching and support to a major facilities management supplier to hospitals in Leeds, London and Bristol, improving response times from an average of 8 to less than 4 hours and reducing their adherence to SLA by 75%. Improving the radiology department average leadtime for non-critical cases from 6 weeks to less than 2 in a Major Midlands Trauma hospital.Petrochemical
Acting as a Lean Coach, supported a Lean Manager rollout initiative by a global energy and petrochemicals company in Denmark and Lead trainer in Nigeria. European CI coach for a FSTE 100 Oil and Gas company, deploying Lean Sigma in their downstream retail business through training, coaching and developing systems and procedures resulting in over $34m of bottom line savings. As part of a full scale Lean deployment team across a national Oil and Gas company in the Middle East, my role was focused on the HR function improving processes such as recruitment, planning, development etc. Recruitment and on-boarding times were reduced by 50%.Printing
Training and mentoring a Lean Six Sigma team to improve several processes within a currency printing organisation in Kenya. The project released £2m of saleable capacity and saved costs of £250,000 over a four month period. Coaching and mentoring several Lean Six Sigma projects to reduce machine set-up times from 42 to 16 hours, inventory reduction from $12.4m to $3.0m and improving Overall Equipment Effectiveness from 52% to 65% improving productivity by over $1.5m.Utilities
Training and coaching several projects in the Liquid Natural Gas division of a major UK Utility company. Coaching and supporting skills development and process improvements in the Human Resources function of a large UK National Utilities company as part of a large deployment. Full end-to-end process improvements include; Disciplinary, Resourcing, Strategic Workforce Planning, Ill Health Retirement & Performance Improvement. Times cut from over 100 days to 35 days for Disciplinary and from 140 days to 95 for recruitment.Previous Clients
- AAT Composites Pty
- Arla Foods UK
- Asda
- Avery Dennison
- Balfour Beatty Plc
- The Blackstone Group L.P.
- Bombardier Transportation
- De La Rue
- Gardner Denver
- GE (several)
- GM Korea
- Instarmac Group Plc
- Laminar Medica
- Linread Aerospace Ltd
- National Grid
- NHS
- Petroleum Development Oman
- Recaro Aircraft Seating GmbH
- Royal Dutch Shell
- SPS Technologies Ltd
- Trelleborg AB
- Vauxhall Motors
- Vestas Wind Systems A/S
Liz Ferguson
Liz is a highly experienced consultant with deep transactional process experience.
She is a Ford and Six Sigma Academy certified Six Sigma Master Black Belt from Jaguar Cars Ltd.
Since 2002 Liz has gained extensive experience in Insurance, Finance, Call Centres, Food Manufacturing and Oil and Gas.
Email: contact@process42.com