Lee Littlejohn

Accomplished manufacturing professional with over 20 years' experience leading quality, compliance and continuous improvement activities within fast-paced engineering and manufacturing environments. Proven ability to improve operational performance, lead cross-functional initiatives, supervise teams and deliver measurable business results. Extensive experience in ISO 9001 quality systems, auditing, supplier management, root cause analysis, risk assessment and stakeholder engagement.

Successfully delivered improvement programmes resulting in significant cost savings while maintaining high standards of quality, safety and customer satisfaction. A proactive and adaptable leader with a strong focus on operational excellence, problem solving and continuous improvement.

Group Quality & Compliance Controller at Woodpecker Flooring (2025-01 – Present)

Recruited to support the business in addressing a significant product quality issue that had resulted in a high volume of customer complaints and product failures.

• Led investigations into product performance concerns, analysing complaint data, identifying trends and determining root causes to support long-term corrective actions.
• Conducted site visits to customer properties to inspect flooring installations, assess reported defects and determine the most appropriate resolution.
• Liaised directly with customers to explain findings, manage expectations and negotiate suitable outcomes, including corrective actions, replacements and refunds where appropriate.
• Worked closely with internal teams, suppliers and stakeholders to identify contributing factors and implement effective corrective and preventive actions.
• Ensured products, processes and documentation complied with relevant national and international standards, customer requirements and company quality procedures.
• Planned and conducted internal audits, supporting compliance, continuous improvement and quality assurance activities.
• Produced and maintained First Article Inspection Reports (FAIRs), technical documentation and quality records.
• Created, controlled and maintained master samples to ensure product consistency and adherence to approved specifications.
• Developed, reviewed and updated technical specifications, technical data sheets and control plans.
• Supported FSC and PEFC certification requirements, ensuring ongoing compliance and successful audit outcomes.
• Contributed to the successful completion of a major product quality improvement programme, helping the organisation identify and address the underlying causes of customer complaints.

Supplier Quality Assurance Engineer at Bailey's Caravans (2019-10 – 2025-01)

• Led the Reject Control Team, providing supervision, support and direction to team members while maintaining high standards of performance and accountability.
• Managed supplier quality concerns from identification through to resolution, utilising structured problem-solving methodologies including 8D, 5 Whys and Ishikawa Analysis.
• Developed and implemented a company-wide internal reject reduction programme which reduced quality-related losses from £3 million to £2 million.
• Worked closely with suppliers, customers and internal stakeholders to improve product quality, reduce non-conformances and enhance customer satisfaction.
• Managed supplier reject processes, including investigation, containment activities, corrective actions, returns and recovery of associated costs.
• Maintained oversight of ongoing supplier 8D investigations, ensuring actions were completed and verified within agreed timescales.
• Produced and presented weekly quality, performance and cost reports to senior leadership teams, highlighting trends, risks, root causes and improvement opportunities.
• Conducted root cause investigations into internal and external quality concerns, implementing corrective and preventive actions to reduce recurrence.
• Supported risk assessment and risk management activities, identifying potential quality risks and implementing mitigation strategies.
• Collaborated with production, engineering and purchasing teams to improve manufacturing processes and supplier performance.
• Contributed to maintaining compliance with ISO 9001 quality management requirements and continuous improvement objectives.
• Acted as a key liaison between suppliers, customers and internal departments to ensure quality expectations were understood and achieved.

Quality Technician at Bailey Caravans (2016-02 – 2019-10)

• Sign-off of completed caravans and motorhomes.
• Quality inspections and customer standard verification.
• Analysis and reporting of quality performance data.

Junior Field Engineer at Northern Automotive Systems (2013-02 – 2015-11)

• Customer liaison and product inspections.
• Layered process audits and control plan development.
• Calibration and training support across the business.

Quality Technician at Northern Automotive Systems (2004-02 – 2013-02)

• Process audits, inspections and production support.
• Measurement and testing of production stock.
• Maintenance of quality records and databases.

Quality Auditor at Northern Automotive Systems (2002-11 – 2004-02)

• Finished goods audits and production line audits.

GCSE in Mathematics – CWMCARN GMS, Newport

GCSE in English – CWMCARN GMS, Newport

GCSE in Double Science – CWMCARN GMS, Newport