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CV, Project Management Consultant Looking Globally

I am currently available for work
Serial No: 47121
(08/06/1960, male)
List top 5 skills: lean management, manufacturing operations, operations management
Short Bio:

Shrewd production/manufacturing leader, specialising in future-state Lean Operational Excellence implementation; World class manufacturing; people, and end-to-end process optimisation in unionised/non-unionised organisations

Deep domain experience in leading end-to-end production/manufacturing and associated operations in several large disparate manufacturing organisations - (blue chip aerospace precision engineering/pharmaceuticals/postural assistive technology products/ consumer).

Current location: 

Northern Ireland, United Kingdom - View on map



Preferred Sector of Employment: 

Manufacturing and Operations

Spoken languages: 


Locations I am interested in working:



• Instituting best manufacturing practices.

• Maximising customer-added-value and embedding measurable Continuous Improvement.

• Hands-on people and end-to-end process optimisation.

• Project managing capital projects.

• Stringent financial control.

• Leading / motivating production or manufacturing and associated operations (Production Planning and Control; Engineering; HS&E; Quality; Global Supply Chain; NPD/NPI; Customer Services; Warehousing; Distribution/Logistics).

• Delivering multi £M capital projects in-full, on-time, within budget.

• Customer-focused with excellent people and relationship building skills.

• Championing lean OpEx.

• Current / future state value-stream-mapping to eliminate waste, cost and risk, re TPS.

• Project managing end-to-end New Product Development/Introduction.

• Leading technology transfers and establishing satellite operations.

• Building highly effective cross-functional teams and promoting self-direction.



David West Lean Manufacturing
Op. Ex and Project Management Consultant
10A Main Street Hillsborough BT26 6AE

Jan 2014 – present

• Delivering project management and production / manufacturing management consultancy.

• Recently completed an administrative/design/engineering contract for a start-up in ROI for all-new bathroom consumer durable products involving – Aug 2014 – Feb 2016

Securing development grants with Cavan Enterprise Board / Enterprise Ireland.

Researching best-in-class products throughout EU.

Project managing the design brief/3D CAD product detailed design and grand assembly/technical specifications/packaging specifications/installation instructions of all- new “greenest” innovative ranges of frameless shower enclosures and wet room products.

Prototyping and independent testing including CE.

EU Design registration and Patent Pending protection.

Managing preparation for production by a preferred Chinese manufacturer including stringent QC protocols and failsafe systems.

• Supplied operations consultancy to Prodieco Ltd. Dublin. Specialist supplier of bespoke high speed pharma blister-pack tooling systems for the global pharmaceutical packaging sector compatible with OEM plant/equipment – specifically – IMA, Uhlmann, Marchesini, Bosch, Klockner/Mediseal, CAM, Romaco, Heino, Ilsemann, Farcon, CKD. Remit was to assume hands-on ownership of all manufacturing operations (including validation and compliance to Factory Acceptance Tests) to optimise departmental outputs – whilst developing a new cellularisation regime prior to the translocation (to new site) of all manufacturing plant and associated operations. Jan 2014 – May 2014


Flair International Ltd., Bailieborough, Co. Cavan. (€16M t/o. Design and manufacture of bathroom consumer durable products).
Operations Director
Jan 2002 – Oct 2013

• Responsibility for all domestic (Ireland) and overseas (China) manufacturing operations (Production/HS&E/Engineering/Procurement/Production Control/Warehousing and Logistics/Customer Care/QA:QC) . Reporting to the CEO.

• Delivered a lean OpEx Toyota-Production-System-based improvement program which boosted efficiency from 67% to 94%.

• Assisted in the delivery of all-new customer-specific product ranges which facilitated entry into new EU markets and massively increased profitable sales (€10M to €16M).

• Created an all-new NPD team and process re-engineered the NPD/NPI function to incorporate Six Sigma DMADV. NPD lead-time reduced by ~75%.

• Reduced raw material costs by >48% by re-sourcing from Europe to China.

• Reduced manufacturing cycle times by almost 40%.

• Key player in formulating and delivering a 6 – 9 year business strategy.


Norbrook Laboratories Ltd., Newry, Co. Down. BT35 6JP. (£260M t/o. Veterinary/human pharmaceuticals for global market).
Head of Engineering and Head of Primary Production
Jan 1999 – Nov 2001

• Reported to the Chairman. Responsible for HS&E; facilities engineering and maintenance; new production plant process-design and engineering; project managing the design/engineering/commissioning/validation of all new manufacturing suites.

• Responsible for all primary chemical production (24/7) – on two sites.

• Successfully specified/designed/engineered/constructed/commissioned four all-new multi £M manufacturing suites and high-speed packaging systems.

• Reduced WFI (water for injection) down time in Factory 1 from 16 – 2%.

• Partnered with all production/operations personnel to assist in optimising OEE.

• Implemented an all-new TPM program on both sites.

• Collaborated with the R&D chemists to prove-out every new primary chemical process at pilot scale ahead of main-stream production and to optimise yields.

• Project managed the specification and commissioning of a multi £M methanol distillation recovery system.



University of Ulster 1993 – 1996

HND Mechanical / Production Eng
Belfast College of Technology 1986 – 1990

BSc. Hons. Combined Sciences
University of Ulster 1979 – 1983



Start-up Workshop – Enterprise Ireland 2015

Lean Transform / Team based cellular autonomy – HOSCA 2013

E.U. R.E.A.C.H. Compliance Forum. Enterprise Ireland (EI). 2012

Occupational HS&E case law seminars. Irish Business and Employers

Confederation (IBEC) 2012

Employment case law seminars.IBEC. 2010

OEE in IEE – The 6 Big Losses. EI. 2009

Occupational HS&E Companies Forum. IBEC. 2008

Innovation and R&D Management. Innovator. 2006

Aircraft Industry Seminar – business simulation. AIMS. 1994

Project Management. Lucas Project Management Consulting. 1993

Theory of Constraints / practical workshops for cells. Goldratt Institute. 1992

Boeing 5S program. 1989

Six Sigma DMAIC. Boeing (on site Queens Island) 1989

Team Dynamics – Building Effective Teams. Outward Bound Cumbria. 1989

Cellular Application – Cell on a single base. Career Track International. 1988

Implementing Self-Directing Teams. Outward Bound. 1987

Leadership Training and Development. Outward Bound. 1985



Proficient in Microsoft Office suite – Excel / Outlook / Word / Powerpoint / Project.