Line first pass yield averaged 58% from September 2024 to March 2025, with individual weeks at 100%. Teams were given direct ownership of quality, and scrap was investigated daily.
Read the case studyIn two years, across 260 processes. The 3x3 programme took operator capability from 79% to 100% across three roles in five months.
Read the case studyIn its first year, SafetyQube, an EHS management system, logged 324 reports. I co-implemented it and raised 108 of them, twice as many as the next highest reporter.
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Operations leadership evidence
Running a line to a set of measures, and developing the people who run it.
SQCDP interview evidence
Interview evidence organised on the SQCDP framework: Safety, Quality, Cost, Delivery and People.
Open dashboard DashboardSkills matrix and cross-training impact
Skills by operator as radars or a matrix, the 3x3 cross-training programme, and how I developed people.
Skills Matrix Builder
Build a matrix for any team. A level only counts once someone other than the operator has signed it off, sign-offs expire, and single points of failure and the next people to cross-training are highlighted.
Open tool DashboardCompany Skills Dashboard
Every team's skills matrix rolled up into one management view. Shows cover against target, critical skills with too few signed-off people, sign-offs about to expire, and where the manager can act.
Open dashboard ToolOEE and downtime tracker
Record shifts and stops, work out availability, performance, quality and OEE from the counts, and rank the reasons time was lost in a Pareto. Leaves out runs with impossible or uncheckable data.
Open tool ToolDaily management board
A tier meeting board for Safety, Quality, Delivery, Cost and People. Readings against target, the reason for each miss, actions with owners, what is escalated, and a check that every action has been independently verified. Opens with made-up example data.
Open tool ToolKaizen and improvement idea log
Ideas from the floor with an owner, expected benefit, decision and result. Flags ideas waiting too long, people not told the outcome, and benefits claimed without an independent check. Opens with made-up example data.
Open tool ToolSchedule adherence
Planned against actual output by hour or day, with the reason for every miss. Shows blocks on plan, units short and over, and a Pareto of reasons using the OEE reason list. Opens with made-up example data.
Open toolContinuous improvement delivery
Finding the root cause with data, measuring the work, and making the gain stick.
DMAIC improvement board
Lean Six Sigma Green Belt project on First Pass Yield at Stage 8 of the caravan line, from Define to Control.
5 Whys root cause analysis
Ask why with evidence at each step, test the logic in reverse, then set actions and verify the fix held. Loads a worked example from a real stoppage on Line 8 and prints as a one page report.
Open tool ToolLine balancing (yamazumi)
Timed work elements placed at stations and charted against takt. Shows balance efficiency, the slowest station and the fewest stations the arithmetic allows, and flags untimed, unclassified or unassigned elements and times nobody checked. Does not check the order of the work. Opens with made-up example data.
Open tool ToolStandard work combination sheet
Walking, manual and machine time for one operator on a single timeline against takt. Shows the cycle, the waiting and where the machine sets the pace, and flags a sheet that has no key points, no independent check, no approval or a lapsed review date. Opens with made-up example data.
Open tool ToolCycle time and waste analysis
Time observation study with VA/NVA split, takt time comparison and a TIMWOODS waste breakdown, as a bar chart and a radar profile. Works for any process, timed live in the browser.
Open tool ToolStandard minute value tool
Run a time study, calculate SMV, line efficiency and production targets, with a formula reference, practice problems and MOST sequence models.
Open tool Dashboard7S audit review
Workplace organisation audit covering Sort, Set, Shine, Standardize, Sustain, Safety and Spirit. Data stays on the device by default, with optional shared collection through a Google Sheet.
Open dashboard ToolSIPOC and value stream mapping
Scope a process with a SIPOC, then map the current state: cycle times, queues, takt, lead time, process cycle efficiency and rolled throughput yield. Prints as a report.
Open tool ToolSPC control chart tool
Individuals and moving range, or X-bar and range, charts with limits set from a baseline you choose. Marks each signal with the rule that fired, and shows Cp and Cpk only when the baseline is valid.
Open tool ToolGemba walk tracker
Log what you see on a walk and trace each observation to its owner, the evidence that closed it and the re-walk that checked the fix. Links every finding to an SQCDP measure and a date.
Open tool ToolA3 problem solving sheet
One page from background to follow-up. Flags an unconfirmed root cause, blame wording, countermeasures with no independent check, and a close-out where the result was not measured or the change was not standardised. Prints on A3. Opens with made-up example data.
Open toolEHS and operational safety leadership
Safety evidence and management system readiness, built from scratch.
EHS Readiness Dashboard
Five tabs: overview, safety evidence, an ISO 14001:2026 self-assessment, the H&S management system on the POPMAR model, and a qualifications roadmap.
Open dashboard DashboardRisk assessment register
A 5 x 5 risk register where residual scores only count once a control is verified working. Flags missing evidence, stale checks and High risks that lack a second reviewer.
Open dashboard DashboardSwiss Cheese layers of defence
Layers of defence tested with real check counts. Shows cautious figures, how weak the evidence is, and how much the layers may fail together. Links to the risk register.
Open dashboard TrackerCorrective action tracker
Actions from audits, incidents and risk reviews, tracked to closure. An action only closes once someone other than its owner has checked that it works. Flags overdue actions and move-on dates.
Open tracker ToolBow-tie Builder
A hazard drawn as a bow-tie: threats on the left, consequences on the right, barriers between. A barrier only counts once it is verified working, and every path with none is shown as a risk.
Open tool ToolQuick Exposure Check
Ergonomics exposure for back, shoulder and arm, wrist and hand, and neck, scored from observer and worker answers. Prints a one-record assessment and keeps a saved history.
Open tool ToolCausal tree builder
An incident traced back through immediate, underlying and root causes as a tree of facts. Flags assumed evidence, branches that stop before a system cause, and actions nobody independently checks.
Open tool ToolIncident and near-miss tracker
Logs incidents and near misses, checks each against the RIDDOR 2013 reporting rules, and shows overdue reports, uninvestigated serious events and actions closed without an independent check.
Open toolThree case studies
Each one says what the problem was, what I did, what changed, and where the evidence is. Figures are as stated on my CV and the linked dashboards.
Quality: line first pass yield from an average of 58% to 92%Caravan production line
The problem
Line first pass yield averaged 58% from September 2024 to March 2025, and fell to 43% in September 2024.
What I did
- Gave shop-floor teams direct ownership of quality.
- Ran daily reporting and root-cause investigation on production scrap, and turned the findings into corrective actions.
- Audited SOPs and QVAs to 97.7% critical process coverage.
What changed
- Line first pass yield reached 92% in July 2025 (to the 15th), with individual weeks at 100%. The tracker ends on 15 July 2025, so it does not show whether this held.
- Vehicle defects down 40%.
- Damaged-in-Production scrap costs 17.7% under the annual budget.
People: skills cover from 36% to 86.6%Team of 29, 260 processes
The problem
Skills cover was 36%, with single points of failure across the 260 processes the team ran.
What I did
- Built and kept a bay-level competency matrix covering all 260 processes.
- Designed and led a cross-functional 3x3 training programme.
What changed
- Team skills cover from 36% to 86.6% in two years, with 44.2% cross-coverage and single points of failure removed.
- 11 of the 29 team members fully skilled on the matrix.
- Operator capability from 79% to 100% across three roles in five months.
The evidence
- Skills matrix and cross-training dashboard
- Skills matrix builder, with sign-offs that expire
- Company skills dashboard
Safety: from compliance to ownershipWith the Head of Health and Safety
The problem
The aim was to move the team from compliance to genuine safety ownership.
What I did
- Worked with the Head of Health and Safety, and co-implemented SafetyQube, an EHS management system.
- Raised 108 of the 324 site reports logged from April 2025 to March 2026 myself (102 near misses and hazards, 6 accident reports), 33% of the total.
- Carried out ergonomic (QEC) risk assessments and daily PUWER machine checks.
What changed
- 324 reports logged in the first year, from April 2025 to March 2026, raised by 22 people.
- Top reporter on site: 108 reports, against 52 for the next highest.
- My own reports rose from 19 in April to June 2025 to 45 in October to December 2025.