Manufacturing Improvements Ltd Mick Ruggles

2014 2016

Summary A multi skilled Manufacturing Consultant taking a new approach to Improvements.

Combining 34 years of Technical Manufacturing experience in the food industry with Lean tools & techniques facilitation.

• A multi-skilled manufacturing improvement consultant with 34 years experience in the food industry thriving on Projects and Interim Roles.

• Site Survey for CIP Optimisation and Validation creating savings in the usage of Chemical, Water, Energy, Effluent & Time.

• Improving groups or processes by combining the facilitation of the LEAN methodology and technical knowledge.

• Processing and filling Production Management and Team Building.

• Commissioning and set up of new plant to production specifications, multi streamed CIP system control and rationalisation.

• Troubleshooting within a processing plant and working with engineering support on modifications on design.

• Working toward Goals with customers and suppliers. Building teams and developing.

• Creation & Running of complete Cleaning & PM Schedules to improve audit results and reliability of plant.

Experience

Filling & Processing Management:• Yogurt, Milk, Cream, UHT Semi Skimmed Milk & Cream, Milk Shake Base.• Yogurt Fruit Conserves, Jams, Fruit Sauces & Bakestable Fruits.

CIP Optimisation & Validation:• Monitoring of CIP Sets and it’s cleans creating savings in Chemicals, Water, Energy, Effluent &

Time.• Calculating required flow rates for CIPs looking at Laminar, Transitional & Turbulent flow

through the Reynalds number.

Commissioning & Rationalisation of New Plant:• Commissioning and set up to specification of new plant.• Modification of 3 tank fruit cooker plant to improve CIP & lower takt time of batches.• Commissioned New 3 bay Cream Intake Bays & 5 stream CIP system, including rationalisation of

cleaning recipes whilst aligning with existing site systems.

Testing New Systems & Processes

Testing New Operations on Sattline Automation System

Testing New Systems & Processes

Testing Operations on New CIP System

Post Commissioning Training

Post Commissioning Training for Process Operators and Technicians

Operational Cleaning Schedule & Hygiene Control Sheet

CIP System installed for Mobile Tanks,

CIP System for Mobile Powder Mixing Tanks & Post Commissioning Training

AchievementsTechnical Improvements:

• Responsible for improving RFT (Right First Time) measurement for all of site production from 68% to 94%.

• Redesign and implementation of Fruit processing plant valve configuration, to reduce CIP time by 55%, and increase OEE by 22%

• Rationalisation of 107 site CIPs to make an annual saving of £180K in Chemical usage & Effluent Costs

• Ran SMED changeover reduction programme , which reduced the CIP time by over 50% equating to £15,000 worth of product produced a week.

• Increase capacity in R&D customer sample creation from 700/month to 1000/month avoiding the creation of a new R&D sample lab.

• Drove and applied the processes to achieve ISO14001 Environmental accreditation. • Project Managed a Powder tumbling tank CIP system from design, through installation,

commissioning, validation, documentation and staff training. This enabled the continuous use of the tanks for filling; removing all product and allergens from the tank. Tank clean turn around time set at 30 minutes compared to 1hr manual cleaning time. The cleaning system ensures no cross contamination compared to manual cleaning.

Experience

Training:• Post commissioning training for processing staff and technicians for new 5

stream CIP set and 3 bay cream intake reception.

• Extensive CIP training giving a complete understanding of Chemicals, Targets for Step Sequences, Calculating Flow rates and Process Design for CIP Sets.

• Lean Awareness training with Simulation for 270 staff at Kerry site in Tenbury Wells including the senior management team at Tenbury Wells and a French based Kerry Group site.

• 5S Training and facilitation for production processing and filling lines.

5S Auction Within Manufacturing

Production Filling Line 5S Auction

Lean Experience

Lean Manufacturing Project Facilitation and Training:

• Lean Awareness Training for Staff and Management

• 5S and Kanban implementation for Site

• SMED Changeover Reduction

• Value Stream Mapping

• Kaizen Blitz Project Workshops

• KPI Deployment

Big Picture Mapping Creation

Mapping the Process during a Lean Project

SMED Analysis SMED Analysis

Workshop with a Cross Functional

Team.

Team Experience

Team Building:

• Through Communication and Approach Skills

• Assertiveness Coaching

• Understanding wider scope of work, customer value and avoiding silo thinking

• First Lean Project Team for Kerry Site, with cross functional members working together through empowerment.

• Process Management team responsibility to work together and share goals and KPI targets.

Qualifications• 2Year Dairy Process Apprenticeship at Clifford Dairies, Bracknell

• City & Guilds Dairy Science Degree (Dairy Science and Fresh Dairy Products)

• City & Guilds NVQ Level 2 Manufacturing Skills

• HACCP Level 3

• NEBS Management Diploma

• Intermediate Food Hygiene Certificate

• 1 Year Lean Coach Training Course with Independent consultant at Kerry Ingredients.

Summary

A multi skilled Manufacturing Consultant taking a new approach to Improvements. Combining 34 years of Technical Manufacturing experience in the food industry with Lean tools &

techniques facilitation. • A multi-skilled manufacturing improvement consultant with 34 years experience in the food industry thriving on Projects and Interim Roles.

• Site Survey for CIP Optimisation and Validation creating savings in the usage of Chemical, Water, Energy, Effluent & Time.

• Improving groups or processes by combining the facilitation of the LEAN methodology and technical knowledge. • Processing and filling Production Management and Team Building.

• Commissioning and set up of new plant to production specifications, multi streamed CIP system control and rationalisation.

• Troubleshooting within a processing plant and working with engineering support on modifications on design.

• Working toward Goals with customers and suppliers. Building teams and developing.

• Creation & Running of complete Cleaning & PM Schedules to improve audit results and reliability of plant.

Where Improvements are

Manufactured !