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Steven FosterCurriculum Vitae Cover Sheet
Current Position: Head of Maintenance (Group)
Current Company: United Cartons Industry Company (UCIC), Jeddah, KSA
Education: BEng Honours Degree (2:2) in Manufacturing Systems with ManagementBTEC National Diploma in Mechanical & Manufacturing EngineeringCity & Guilds in Mechanical & Manufacturing Engineering
Accreditation: Six Sigma Black Belt
Technical Skills: FMEA, DOE, SPC, VSM, Root Cause, DMAIC, Process Mapping, Pareto, Chi-Squared, Fish Bone Diagrams, P.U.W.E.R, L.O.L.E.R, cGMP, Manual Handling, 5's, Kan-Ban, Cellular Layouts
Personal Profile:Experienced and innovative Engineering / Maintenance Manager who leads by example, with Production / Projects Engineer experience and also apprentice trained engineering skills across a wide range of machine expertise
Highly Articulate, confident and persuasive team-builder, able to motivate and communicate to both upper management and shop floor personnel
Excellent planning, costing, sourcing and installation skills of new plant machinery, and the relocation of existing machinery utilizing Permits to Work (General, height, C.S.E & hot) , risk assessments, inductions and training schedules
Excellent team person either as part of or leading a team, I can also work alone using my own determination, creativity and technical skills to problem solve
Focused, but flexible approach to projects, maintenance (both planned and breakdowns) and work well under pressure
Honours Degree in Manufacturing Systems with Management (2:2 BEng)
Experience:Managing three plants maintenance departments with a complete team of 72 technical staff, control of a R & M budget of SR32M, and capital projects of SR5m. Driving down unscheduled breakdowns, improving PMI schedules and control of spare parts and the reduction of inventory. Managed successful shuts in Jeddah during both Ramadan and Hajj (EID) holidays Managed 9 major shuts on the Holcim site – ranging from a Silo clean out to a full cement mill, utilising both Holcim Mill’s team and a large number of contractors. All shuts have come in under / on Budget with no extended delays. Cement Mill 1 Shut came in 4 days early and $150k under budget Excellent safety record – zero LTI’s, MTI’s (Medically Treated Incidents) & 1 FAI (First Aid Incident), fully trained ICAM investigator and Completed Safety Leadership course (Internal).
Six Sigma Black Belt, working on projects (using DMAIC) in both lean (Value Stream Mapping) and Six Sigma Design of Experiment (D.O.E) on wear ring strip production (targets of 75% waste reduction ($20K) and increased capacity ($350K)) from raw material through to dispatched finish goods for customers. Six Sigma project on material defects (tube production) and causes.
Great analytic skills in gathering raw data and transferring, filtering and analysis to reporting
Proficient in the use of all Microsoft packages, S.A.P, AutoCAD, Minitab, Sigma-works, Process Modelling Experienced at working on projects from rough concept designs to final installations, including writing documentation for Factory Acceptance Trials (F.A.T) and Site Acceptance Trials (S.A.T), Change Control and validation documents to current F.D.A regulation
Good budgeting skills, looking after large ($3.2m) and small ($650K) revenue budgets, including writing Capex's for the securing of funds, and controlling a tooling spending budget ($130K) for the financial year (2 years running)Delivered and installed (as a team leader or part of team) 18 machines to site, including 5 manual handling associated projects
Fully trained risk assessor, manual handling trainer and worked for the Health & Safety department on an 18 month secondment, carrying out risk assessments for the engineering department and producing a register, which lead to implementing manual handling changes within the factory and offices
Used a number of lean manufacturing tools to improve the company’s production problems, including Value Stream Mapping, 5's, cellular production (grouping families of parts), Kan-Ban systems, process flow (reduction of rework & parts movement) and waste reduction
Carried out quality testing on products and customer returns, producing detailed reports on the findings
Designing of jigs and fixtures for machines and general working, including manufacturing proto-type models
Achievements:United Cartons Industry Company (UCIC), Jeddah:Reduced downtime across the plants: P1 – From 3.4% to 2.6% (YTD), P2 – From 5.7% to 4.3%, P3 – From 2.7% to 2.3%R & M Budget gone from SR1.1m over budget (2015) to SR2.47m under budget (YTD)Reduction of spare parts in stores: P1 – 1.5%, P2 – 1.4%, P3 – 2.2% by reviewing and setting Min / max stock levelsReduction of inventory (old 2004 to 2013 & Obsolete) P1 – 40.5% (SR1.66m), P2 – 49.5% (SR0.7m), P3 – 55% (SR0.5m)Reduction of consignment stocks: P1 – 36% (SR0.4m), P2 – 23% (SR0.12m). P3 – 14% (SR0.36m)Holcim (New Zealand) Ltd, Westport:Started off as Auxiliaries Maintenance Manager, before being promoted to Maintenance Manager – Mills, now Maintenance Manager – Kilns / MillsRunning a department of 3 mechanics, 4 fitters (Aux Dept.) and 5 fitters, 4 labourers (Mills dept.), now running a team of 18 maintenance personnelWorking closely with Production Supervisors and operations to ensure better running of the plant via good planned maintenanceSuccessfully running a maintenance budget of $3.2m (2012) coming in $60.5K under budget, with a $3.713m budget for 2013, and now running a budget of $10.3m , currently standing at $404,000 under budget YTD (Taken on 30th nov 2013)Completed 9 shuts on site, bring them in on time / early and with in budgetSafety record: Zero LTI’s, Zero MTI’s and 1 FAI (First Aid Incident) – Contractor burnt hand on hot molten steel whilst gas cutting bolts offCompleted ICAM investigator course – to carry out high and medium level investigations on site and other Holcim sites when major incidents occurSafety leadership Development (Parts 1 & 2) – Driving safe working within the group and leading teams / individuals through safety on Holcim’s “Zero Harm Journey”Practical Leadership Skills 1: The Self-Aware Leader4 Quadrant Leadership – New Zealand Institute of management Stepped in as Acting Engineering Manager whilst Engineering Manager has been away
Amcor Kiwi Packaging (Hastings)Running the Maintenance department (5 staff, plus numerous contractors)Planning the daily, weekly, monthly maintenance, annual shutdownsRunning an R & M budget of $1.3m, coming in under budget ($50,000), planning new budgets and forecastingWriting all Capex, User requirement Specifications for new capital and running the project management of them (new machine $2.3m, trim master $152K) Reduced maintenance break downs from 5.5% to 2.8% (Mechanical) & 1.356% to 1.0% (Electrical) Installation of the new corrugator conveyor system on time and under budgetInstallation of the new load former and conveyor system for the gluer on timeReduction of set-up times on the machines ranging from 2.89% to 37.37%Increase in productivity on the machines ranging from 3.3% to 11.8%Reduction in the machine downtimes from 1% to 5.8% across the factorySuccessfully run the converting department (15 people) as acting supervisor when the main supervisor has been away and also acting supervisor for maintenance (6 people) when the supervisor has been awayRun successful fish bone and FMEA problem solving teams leading to the above successesCarried out numerous studies, in waste reduction, production efficiencies, material movement and plant layouts Trelleborg Sealing SolutionsWaste reduction project (part of Six Sigma Black Belt project) savings of GBP 70K / yr.New pallet loading CNC machine for milling section: Cycle time reduction success with cost savings of GBP46K/yr.Machine Study (increasing speeds & feeds) on CNC cells, improved cycle time on bush work by 24.5%Sourced, purchased and packaged / shipped machinery for plant in china, (2 CNC's, 4 other small machines) all successfully installed and working.Introduced a new mandrel manipulator in the wrapping extract process to handle large (+40kg) mandrels off the line into the extract machine, removing the need for the operator to handle themExtended the marine crane system as part of the large wrapping projectInstalled 9 new machines and moved 12 existing machines around the Rotherham site without any major incidents / accidents
Smith & Nephew Medical LtdSingle Minute Exchange of Dies (SMED): Cost savings GBP66K / yr., reducing die cutting changeovers from 5 hours to 2 hours, two fold projects also reduced manual handling risk assessment score from 165 to 30Reject Bin Improvement project: Cost savings of GBP44K / yr.Manual Handling: Large roll manipulator for Allevyn line; picked up, rotated and loaded large rolls of film (+80Kg) on to the machineManual Handling: Large roll manipulator for Flow wrapping section, picked up rotated and loaded rolls of vacuum film (80Kg)Vacuum bag handling unit to paste division: Moving 25kg bags of material from clean to dirty side of airlock (4 x 250kg pallets at a time)Various small changes to working practice within the Engineering department reducing lifting of heavy awkward items whilst bending, twisting and crouching in machinesInstalled (using a team of riggers) 15 new machines, and moved 7 existing lines around within the Hull site without any major incidents / accidents.
Euro Power Hydraulics LtdCNC Cellular project: Grouped families of parts and set CNC section up in to small cells: reducing set-up times per machine. Saving GBP18K/ yr., removed 2 heads from the section saving GBP38K/ yr.5's on hose assembly line: Reduced time looking for tooling / parts. Increased production capacity by 6%, removing need for overtime costs. Cost saving of GBP22K / yr.
Career History:2015 to present United Cartons Industry Company (UCIC), Jeddah, KSA – Head of Maintenance (Group)2011 – 2015 Holcim (New Zealand) Ltd Cement Works, Westport – Maintenance Manager – Kilns / Mills2007 - 2011 Amcor Kiwi Packaging (Hastings): Process Improvement Engineer, then Maintenance Manager 2005 - 2007 Trelleborg Sealing Solutions (Rotherham), Rotherham: Six Sigma Black Belt, Production
(Projects) Engineer
2001 - 2005 Smith & Nephew Medical Ltd, Hull: Manufacturing Projects Engineer
1999 - 2001 Euro Power Hydraulics Ltd, East Yorkshire: Quality Projects Engineer, Continuous Improvement Engineer, Process Engineer
1997 -1997 Reiter Automotive (6month University placement): Technical Assistant
1998-1998 British Steels Technology Centre (7 month University placement): Finite Element Analyst & Plant Condition Monitoring Analyst
1988 - 1991 Taylor Valves Ltd, Huddersfield: CNC Setter / Operator
1985 - 1988 Case Tractors, Huddersfield: Apprentice Engineer, then CNC Setter / Operator Education:1995 - 1999 University of Bradford: BEng Honours Degree (2:2) in Manufacturing Systems with
Management
1993 - 1995 Huddersfield Technical College: BTEC National Diploma in Mechanical & Manufacturing Engineering (7 distinctions, 17 Merits)
1985 - 1993 Huddersfield Technical College: City & Guilds:-General Technology & Mechanical Engineering Practices (Pass & Credit)Basic Engineering & Mechanical Production Technology (Pass & 2 Credits)Basic Engineering Technology (Pass & Credit)Mechanical Engineering & Process Experience (Pass & Credit)RSA Typewriting Skills stage 1 (Pass)Engineering competence & technology to NC / CNC part programming level 3 (5 Passes & 8 Credits)
Personal Details:Title: Steven Foster
Date of Birth: 13th January 1969 Address: Arabian Homes – Sierra Village – 8b Deyna
Kaheel Alazdey St. 96Al Zahra DistrictJeddah, KSA
Telephone No: +966 12 662400 Ext. 2712
Mobile No: +966 554448562
E-Mail: [email protected]@[email protected]
Skype Address: fozndebsSkype for Business: [email protected]: [email protected]
Marital status: Married to Debbie with 1 daughter aged 10 year’s old (residing in Jeddah)
Residence Status: New Zealand Citizenship (was permanent resident), KSA Resident (Iqama), British Citizen
Driving license: Clean (New Zealand, UK licenses, Saudi Arabian)
Leisure Activities: Enjoy playing golf and cycling (Rode Tour of the Bay 50Km, Tour De Beautiful 25km, Taupo flyer 100km, around Taupo 40Km stage)
Going to the Gym, ran 3rd stage of Buller marathon this year TravelingSpending time with my daughterWatching all aspects of sport both at amateur and professional levels
References: All certificates and references available Reference contact details for Steve FosterMohnish RikhyGeneral ManagerUnited Cartons Industry Company (UCIC)JeddahTel: +966 12 2244200Mobile: +966 506681899E-mail – [email protected]
Clark NelsonEngineering ManagerHolcim NZ LTDCape FoulwindTel: +64 3 7895834Mobile: +64 21665187E-mail: [email protected]
Paul ColemanShipping Manager (was Engineering Manager until Jan 2013)Holcim (New Zealand) LtdCape FoulwindTel: +64 3 7895871
Mobile: + 64 212427842E-mail: [email protected]
Dave MorrisonManufacturing ManagerAmcor Kiwi Packaging (Hastings)Meihana StreetHastingsTel: +64 6 9748095Mobile: +64 21461720E-mail: [email protected]
Barry RedfearnOperations ManagerTrelleborg Sealing Solutions RotherhamBradmarsh Business ParkRotherhamSouth YorkshireS60 1BXTel: 00 44 1709 789822 (Direct)Tel 00 44 1709 789800Fax: 00 44 1709 374819Mobile: 00 44 7747066178E-mail: [email protected]
