MQ12005 Systems implementation and certification
David was appointed Turner Powertrain Systems (wholly owned subsidiary of Caterpillar Inc.) MQ12005 site coordinator in 2005.
MQ12005 is a CAT certification program primarily driven by section performance data and is now embedded into the organisations ISO 9001 compliant, Quality Management System. The primary aim of the MQ certification programme was to identify key metrics or section indicators for each value stream within a facility and subsequently monitor these metrics against strict performance criteria over time.
Less than optimum performance required targeted action to bring the metrics up to required performance levels in order for evidence packs to be submitted to corporate for certification to take place, a process in which I was involved in, as the appointed assessor for the Turner Powertrain site. A typical pack could include ongoing evidence of statistical capability of Special Characteristics, Right First Time data, scrap costs and PPM monitors.
David successfully managed a two year project to implement the required processes and necessary performance improvements, resulting in certification of all 12 facility sections covering both manufacturing and assembly operations, a significant achievement as not all facilities achieved 100% certification to the standard.
I would not hesitate to recommend David. He was a pleasure to work with & his hard work and attention detail has delivered positive results to the business.
Neil Anderson – Managing Director at Caterpillar Skinningrove Limited.
Six Sigma certified black belt in DMAIC & DMEDI
ISO 9001-2008 Registered Lead Auditor (IRCA Approved)
ISO 9001 Systems maintenance and certification
David was responsible for our sites Quality Systems management and maintenance, including as management representative, all liaison with our external certification body.
Since his initial appointment as Business Systems Manager in 2005, David has successfully guided the business through many third party audits including several re-certifications by the BSI against the ISO 9001 international standard, with minimal disruption to the business and always with added value feedback and outcomes.
As our management representative, David ensured that senior management were appraised of any shortcomings in our business processes highlighted by our internal audit system. This was achieved via report outs and recommendations in our management review meetings which were supported by the appropriate level of data for the business to make the right decisions to further improve our processes.
Andrew Goldspink CEng, MIMechE, BEng(Hons) – Director and Facility Manager
Turner Powertrain Systems
David was brought into project Unity – a new joint venture between RAC plc and Norwich Union Insurance, due to an unacceptable level of quality issues at the customers’ repair centres attributed to parts quality concerns. Stretch targets for reduction of incoming supplier quality rejections and customer returns were set as key objectives for David. To address, he successfully introduced a range of measures including a unique new industry acceptance process for parts quality, resulting in both targets being substantially exceeded.
David, when promoted to Quality Manager for the project, went on to recruit and train a dedicated team to further improve the quality of our products and service to the customer, through a range of measures including implementing supplier selection, approval and development processes in Europe and Asia, customer concern response time reduction, problem parts tracking and fostering joint ventures with key industry partners (Thatcham.)
David is very organised, process driven and keen to go the extra mile to ensure excellence in quality. David also demonstrated an excellent appreciation of a fast moving and in essence, start up business and was instrumental in dramatically improving quality parts availability at point of order for our customers, thus impacting our top and bottom line growth.
An excellent quality systems professional.
David Byrne – Managing Director, project UNITY,
Lex Auto Logistics Automotive crash repair joint venture,
RAC plc and Norwich Union Insurance.
Environmental Management System Implementation And Benefits
When Caterpillar Inc. mandated that all plants and subsidiaries must achieve certification to the Caterpillar Environmental Protection Programme (a CAT internal certification programme aligned with the requirements of the international environmental standard, ISO 14001) As Facilities Manager, I was tasked with implementing the necessary processes at the Caterpillar Wolverhampton site with my colleague – David Barker.
As there was no Environmental Management System in place previously, David as appointed Environmental Representative, set up an implementation project team to build an effective EMS for the site, with input from all the key stakeholders in the organisation.
David’s systems and project management experience proved invaluable as we worked together on addressing the gaps. These included the roll out of spill prevention training and equipment, mapping and monitoring of our waste streams through duty of care visits and compiling a significant aspects register which was ranked for further action through environmental improvement projects. One of the resultant projects – the installation of a waste water recycling plant used for rack washing, not only resulted in reducing our environmental impacts, but also significantly reduced the cost of our special liquid waste disposal. Overall, the company also achieved significant and profitable returns due to improved waste management which were a direct result of the new controlled management system.
As a direct result of the programme implementation, the business not only achieved certification for the EMS, but went on to achieve Caterpillars prestigious Silver award for environmental excellence in recognition for our improvements in waste reduction by adopting the reduce, reuse, recycle methodologies.
Robert Holt – Facilities Manager, Turner Powertrain Systems