Tony Metcalfe - Resume 2015 V1

Anthony Metcalfe

1905/45 Bowman Street, Pyrmont NSW 2009

Phone: 0423 653 715

E-mail: [email protected]

PROFESSIONAL PROFILE

12 years of Lean manufacturing experience as part of a 25+ year career in logistics and procurement within heavy engineering and the Rail sector.

My career in logistics and procurement commenced with Railpart UK Limited, a government entity specializing in the supply of roll ing stock spares to the rail industry – rising through the company from warehouse operative through to warranty manager.

In the early-2000’s I took the opportunity to join Unipart’s Lean division. Initially I was involved with the creation of the Unipart Way, Unipart’s Lean way of working and then developing and delivering training before naturally

progressing into Lean consultancy. Several years of developing and delivering Lean training honed my written and oral communication skills.

• Experience in both Lean program and project

management. Over 10 years of delivery experience including many years in transformations, systems integration, solution delivery and business change.

• Extensive end to end experience covering all Lean project phases from concept and business cases to implementation and benefits realisation.

• Proven track record in delivering large and complex lean projects on time and within budget.

• Managing Continuous Improvement teams in large and small organisations including cross functional teams and multiple stakeholders

• Experience in working with multi -location and matrixed teams.

• Strong communication skil ls, including face to face delivery, client relations, and negotiation

• Strong customer / stakeholder management, relationship and interpersonal skills.

• 25 Years of Rail experience.

• Hands on experience in delivering business improvement in multiple sectors.

• A delivery thought leader with superior aptitude, decisiveness and passion.

• Exercises independent judgment within broadly defined policies and practices to determine best method for accomplishing work and achieving

objectives following lean principles.

• Strong technical background in Lean tools and

Techniques including Six Sigma black belt qualified.

• Proven ability to deliver high quality process

improvements on schedule and under budget.

• Accomplished in the use of MiniTab, a suite of

statistical analysis tools.

• A high achiever with a strong deadline and results oriented focus.

Anthony Metcalfe • 0423 653 715• [email protected] Page 2

LEAN PROJECT SUMMARY

Period Name Synopsis

Jun 10 –

Mar 11

Irish Rail A project focusing on Lean process improvements at multiple client sites in Ireland.

Implementation of the Unipart Way.

Role: Lean Practitioner Savings Achieved across all sites $2m

Team: FTE of 25 Organisations: 6 external

Jan 09 –

Jun 10

RailCorp A project focusing on Lean process improvements at multiple client sites in Sydney


Role: Lean Practitioner

Savings Achieved across all sites $1m Team: FTE of 10 Organisations: 4 external

Jan 08 –

Dec 08

HMRC A project focusing on multiple work streams for Her Majesty’s Government. I was

leading a project that was tasked with reducing the amount of time taken to recover debt from the taxpayer.



Savings Achieved across all work streams GBP 400m Team: FTE of 24 Organisations: 1 external/ 1 internal

Jul 07 –

Jan 08

Vodafone A project looking at the repair of mobile phones. I was targeted to achieve a 20%

improvement in productivity.

Lean tools used included Communication Cells, KPIs, MDI, Standard Work.

Role: Lean Practitioner Savings Achieved GBP 3m Team: FTE of 24

Organisations: 1 external/ 1 internal

Jul 06 –

Jul 07

Sky TV A Project focusing on the picking and packing activities for SKY TV. I made process improvements to the layout and picking process that resulted in a 30% increase in

productivity FROM 16000 lines to 21000 lines

Role: Lean Practitioner Savings Achieved GBP 10m

Team: FTE of 60 Organisations: 1 external/ 2 internal

Mar 06 –

Jul 06

Waterstones Automation of warehouse processes through the Implementation of Vanderlande

Book sorting system

Role: Lean Practitioner Savings Identified: GBP 2m Team: FTE of 8, Peak Staff of 25 in 3 locations

Organisations: 3 internal/2 external


LEAN PROJECT SUMMARY

Period Name Synopsis

Mar 05 to

Sep 05

Unipart

Bogie Cell

A project focusing on the production of train bogies. I was targeted to achieve a 25%

reduction in cycle time. I did this through the introduction of single piece flow, creating a number of work stations and defining a specified amount of work at each work station before the bogie moves to next work station

Lean Tools used included, Value Stream Mapping, Standardised Work, work load balancing, Staff training in Lean tools and techniques.


Savings achieved: GBP 1.2m

Team: FTE of 60 staff Organisations: 2 external/ 2 internal


PROFESSIONAL EXPERIENCE

Unipart Group Australia seconded to UGL Unipart NSW Continuous Improvement Manager July 2012 – current

Achievements:

Setting up a Continuous Improvement team and developing a Team of Unipart Way Lean Champions,

initially seconding team members into the newly created Continuous Improvement team. Creation of a Unipart Way training and mentoring program. Leading the team in delivering level one Unipart Way training to all 350+ FTE on multiple sites. Played a key role in the planning and delivery of a number of Lean projects delivering benefits in excess

of $2m.

Responsibilities:

Initially responsible for the formation of the Continuous Improvement team and developing local employees into Lean Champions. Early responsibilities also included the creation of training and development material for use at UGL Unipart. I was responsible for the delivery of Unipart Way training

to all UGL Unipart staff to various attainment levels, including fellow members of the leadership team. Reporting to the Chief executive and preparing required board reports for Continuous Improvement business unit. I am responsible for the Continuous Improvement 12 month plan. I am also responsible for managing the Continuous Improvement budget and accountable for delivering results.

Unipart Group Australia seconded to UGL NSW Warehouse Manager April 2011 – July 2012

Achievements:

Implemented a new management system for warehouse and logistics functions conjointly with the

Supply Chain Management team. Created a new warehouse and logistics organisational structure to support new ways of working. Developed and implemented a suite of Key Performance measures and enforced performance management against the measures.

Introduced new picking and receiving processes that resulted in productivity gains of 30%. I increased stock accuracy from 69% to over 99% through implementation of cycle counting and good visual management. Reduced overtime by 90%. Introduced Line side deliveries to the operations team.

Responsibilities:

Reporting to the General Manager Supply Chain I was responsible for all warehouse related activity. I

had four direct reports. I was responsible for delivering challenging targets relating to key warehouse processes to ensure business growth. I was responsible for developing and training staff and implementing a succession plan. I was responsible for ensuring budgets were met and outcomes

delivered.


Unipart Rail Expert Practices Lean Expert Practitioner March 2005– March 2011

Achievements:

As part of my current role I have helped to reduce operational costs for a number of clients. One of the major successes was in a transactional environment where we made over £400m saving in operational costs for the client. My most recent contract was working with a major Rail operator in Australia where I helped to develop local Lean capability throughout the depot logistics operation

Responsibilities:

Applying, training and coaching all aspects of Lean Tools and Techniques including, Location Diagnostics, Process Diagnostics, Value Stream Mapping, Culture change, Waste Identification, Kanban, Andon, TAKT, QFD and FMEA.

Unipart Rail UK Limited Unipart Way Practitioner October 2003– March 2005

Achievements:

I helped to coach over 325 people in five core Lean Tools, Communication Cells, Work Place Audits, Standard Work, Visual management and Creative Problem Solving.

Responsibilities:

Training, coaching and applying all elements of the Unipart Way Lean philosophy across the Unipart Group.

Unipart Rail UK Limited Warranty Process Manager December 2001– September 2003

Achievements:

Project managed the introduction of a Warranty Process to support a new Logistics contract Unipart Rail had secured.

Responsibilities:

Working with a team to ensure that the process was in place in time for the contract going live in Jan

2004. Using Tactical Implementation Plans to manage the project, communicating any back spikes to the client and agreeing countermeasures. The project was fully implemented on time.

Unipart Rail UK Limited Account Delivery Manager October 1998– November 2001

Achievements:

I was able to improve the Turn Round time of repairable from 120hrs to 48hrs. I also worked closely with the suppliers to understand and reduce the repair lead-times, in some cases by over half. I achieved uplift in Repairable availability from 65% to 89% without having to inject float. This resulted in

improved fleet availability for the client.

Responsibilities:

Responsible for the delivery of process improvements in the Rail supply chain. Looking at the supply of materials from the Distribution Center to the Rail Depots and the return of Repairable product back to the Distribution Center. Working at a Rail Depots across the United Kingdom to understand and improve

a number of processes to improve Critical spare availability.


Unipart Rail UK Limited Warehouse Supervisor March 1991– October 1998

Achievements:

Creation of customer focused Key Performance indicators

Responsibilities:

Leading a team of around twenty stores personnel in all aspects of warehouse operations. Duties included Resource Allocation, workload planning, completing weekly reports for management and managing for attendance. I was also responsible for identifying all training requirements of the team

and all health and safety related issues.

Unipart Rail UK Limited Warehouse Operative March 1982– March 1991

Achievements:

Meeting and exceeding all daily targets assigned to me.

Responsibilities:

Duties included picking, packing, despatch of rail products, Loading and offloading using a counterbalance Forklift truck, receiving material i nto stock and cycle counting.

CERTIFICATIONS AND TRAINING

Certifications:

NEBBS Supervisory Management Award

Six Sigma Black Belt

Level 5 Unipart Way All Lean Tools

Level 5 5S Workplace Organisation

Level 4 Policy Deployment

Training:

Advanced Excel, Unipart University 2002

Unipart Way Training, Unipart University, 2003

Six Sigma Training, Unipart University, 2003

Lean Manufacturing, Unipart University, 2003

Train the Trainer, Unipart University, 2004

Change Management skil ls, Unipart University, 2004


PUBLICATIONS

I have published a number of articles on Lean tools and Techniques. Some of which are;

“A walk too far” – Kaizen Newsletter Volume 1, Issue 6, December 2013 “Heavy Maintenance Value Stream” – UGL Unipart express , Aug 2014

‘Line side deliveries’ – Kaizen Newsletter Volume 1 issue 8, Nov 14 ‘OCC Circles, our chance to make a difference’ UGL Unipart Express July 2013

REFERENCES

References are available upon request.

Documents

Tony Metcalfe - Resume 2015 V1