Principal Consultant and Founder - TransFormX Consultancy Limited - Lancashire
(2026-09)
Independent operational recovery, transformation and performance improvement consultancy for defence, aerospace, regulated manufacturing and industrial distribution. Independent practice, established September 2026, company number 17453683.
- Founded TransFormX in September 2026 as an independent consultancy for defence, aerospace, regulated manufacturing and industrial distribution, built on 19 years of results delivered in industry.
- Structured 6 engagement routes, from a 2 to 3 week baselined diagnostic to a 3 to 12 month interim mandate, each priced from a £500 day rate and measured against an agreed baseline rather than consultancy activity.
Contracts Manager (Operations), Defence Portfolio - Arco: Experts in Safety, National UK - National UK
(2024-11 - 2026-10)
£29.4m FY27 defence and transport portfolio across 11 accounts, covering 40 sites and 25 FTE; full P&L accountability, reporting to the Commercial Director.
- Protected £17m+ of at-risk BAE Systems contract value at extension, shifting the relationship from transactional supply to strategic partnership through structured commercial recovery and senior stakeholder alignment.
- Lifted on-time-in-full delivery from 86% to 97% across 40 defence sites in one financial year, redesigning SLAs, weekly performance forums and operating routines.
- Cut back orders 40% across 2,600 SKUs and £10m+ of inventory, and reduced replenishment cycle times 30%, by restructuring the supply chain operating model with ABC and XYZ segmentation and real-time inventory tracking.
- Isolated £263k of AWE credit exposure to two SKUs through forensic analysis of 7,548 transactions, proving 97% of value concentrated in the pair and surfacing a root cause internal teams had missed.
- Built the FY27 £29.4m defence forecasting and budgeting architecture across 11 accounts, embedding three S&OP cycles covering £35m+ of billing with seasonal phasing, probability-weighted pipeline and scenario targets.
- Reframed a £494k Network Rail contract-exit exposure to a £157k hard liability as sole commercial lead, separating dedicated from shared stock and modelling three exit scenarios ahead of the June 2026 exit.
QHSE Manager - Eikon Materials - Lancaster
(2023-12 - 2024-10)
ISO 9001, ISO 14001 and ISO 45001 integrated management system; team of 3.
- Achieved zero non-conformances across ISO 9001, 14001 and 45001 external audits by reworking controls, evidence packs and CAPA.
- Shortened audit preparation time 30% and cut claims resolution from 32 days to 4, through a redesigned 5S-based document control system and DMAIC-led process redesign.
- Achieved a 40% reduction in energy consumption and a 23% cut in unplanned downtime through TPM and autonomous maintenance training.
- Reduced supplier-related non-conformances 30% by introducing First Article Inspection into the supplier quality programme.
Quality Manager - Booth Dispensers - Blackpool
(2022-02 - 2023-12)
ISO 9001 quality management, supplier quality and process capability; team of 3.
- Eliminated defects, cutting the rate from 32% to zero, by rebuilding process control and prevention through PFMEA, supplier quality, standard work and error-proofing.
- Led the site through multiple ISO 9001 certification and surveillance audits with zero major non-conformances, cutting internal audit cycle time 30%.
- Increased new-process output 20% and cut in-process defects 15%, delivering a new foaming insulation process ahead of schedule.
- Halved warranty and claims resolution time, from 32 to 16 days, by streamlining the process with value stream mapping.
F-35 Continuous Improvement Team Manager - BAE Systems - Samlesbury, Lancashire
(2021-04 - 2022-02)
Team of 7 Lean Process Engineers.
- Delivered £2m+ in validated cost savings through a Lean Six Sigma Belt programme, coaching Black and Green Belt cohorts across the F-35 improvement portfolio.
- Directed 7 Lean Process Engineers, coaching DMAIC, value stream mapping and Kaizen delivery.
- Developed and rolled out a Continuous Improvement Maturity Framework integrating 5S, Kanban and standard work across the F-35 programme.
Technical Support Process Lead - DePuy Synthes, part of Johnson & Johnson - Blackpool
(2018-10 - 2021-04)
Engineering, maintenance and process integration in a regulated ISO 13485 environment.
- Cut equipment downtime 20% by optimising maintenance strategies using real-time data and reliability analysis.
- Integrated two key production processes, achieving a 50% reduction in equipment usage and a 25% reduction in headcount while maintaining output and quality.
- Maintained full ISO 13485 and 21 CFR Part 11 compliance across multiple internal and external audits with zero major non-conformances.
Lean Manufacturing Manager - Booth Dispensers - Blackpool
(2016-01 - 2018-10)
Cross-functional production and maintenance team of 25+.
- Increased daily output 20% and cut manufacturing cycle times 47% through new work-cell layouts and restructured production areas.
- Reduced defect rates below 1% by establishing critical control points and applying PFMEA before risks reached the line.
- Delivered £150k+ in savings through more than 20 Kaizen Blitz events, process re-engineering and daily management.
