Meet the team

Our coaches

Our team of coaches have international experience across Europe, Canada, USA, Singapore, Australia, China and the Middle East.

They have extensive experience in lean and agile ways of working, digital transformation, change management, continuous improvement, Six Sigma and Scrum.

With our team operating across oil and gas, engineering, finance, manufacturing and construction, to name a few, Practical Business Improvements can provide a resource that has a deep understanding of your work and with the capability to deliver on a successful improvement initiative.

Meet the team

We have worked with clients in a variety of sectors to help streamline their business

View Case Studies
Alison Shaw
Continuous Improvement Coach

Personal profile

Alison is a results-driven professional who has extensive experience in Lean, Agile and Continuous Improvement methodologies.  She is a trained coach and mentor and has experience of working at all levels in an organisation. 

Alison is methodical and rigorous in her approach, and is hands-on, she has successfully delivered numerous major Kaizen Events improving operational, and service, performance, she drives sustainability, process performance, and ownership.  

Alison an experienced Tender Manager with expertise in end to end process mapping within organisations, focussing on value adding activities.  

She is a resourceful team player who uses all her Continuous Improvement skills to support the team and the less experienced within the team.  She has worked in large O&G Service Companies and Operators.

Sample projects

Oil & Gas  – Led a program of Kaizen events to reduce the inventory held at 3rd party Vendors and to rationalise the stock held for the Company in an effort to support the Zero Inventory Management initiative.  Conducted Value Stream Maps and Kaizen events to deliver the improvements. Resulting in $13m in savings through 2019, >$10m of stock made visible to the business, reducing Capex and Opex.

Led a successful improvement initiative to bring Service / Manufacturing Workshops in a large Service Organisation to world class facilities.  Improved the operational performance and safety, by applying workflow techniques and 5S activities through Kaizen Events.   Set up Huddles and Campaign Rooms to track actions and to visualise progress through metrics and maintain sustainability.  Increasing OTD to 85%, with the added benefit of increasing personnel motivation and  ownership of the activities through participation,  recognition and engagement.

Areas of expertise

  • Lean methodologies and agile ways of working
  • Visual management
  • Value Stream Mapping and execution of Kaizen events
  • Kanban
  • Coaching and mentoring
  • Procurement and supply chain management including:
    • Inventory management and reduction in warehousing
    • Vendor management and contract negotiation
  • Communication and stakeholder management
  • Establishing sustainable process performance  governance structures including ownership, KPI’s, controls and benefits tracking
  • Service business processes
  • Tender management
  • Inventory management and warehousing

Key areas of focus

Oil & Gas – Facilitated a Kaizen event to improve plan attainment and break-ins to the plan at St Fergus Gas Plant. Planning, permit rejection / approval processes set up, communicated and rolled out to key stakeholders.  50% reduction in break-ins to the plan. Coached client staff and delivered lean training. Campaign room set up to visualise the break-ins and plan attainment metrics.

E2E transformation programme: Kaizen leader within a lean transformation programme. Conducted end to end process analysis using Value Stream Maps and instigated over 40 improvement projects. Worked with senior stakeholders to obtain buy-in to deliver these projects. 

Led process improvement workshops using the Kaizen methodology. Overall benefits in excess of $50m.

Get in touch with us today sales@pbi-ltd.co.uk

Gary Downs
Managing Director

Personal profile

Gary has over 40 years experience working within the Continuous Improvement arena. Extensive knowledge in Lean, Agile and Six Sigma. He has led transformation projects across many companies; both nationally and internationally.

Gary applies the practical touch to problem solving, using the appropriate approach to solve issues, as opposed to trying to apply a ‘cookie cutter’ approach to all problems.

Gary has worked in many industries ranging from hospitality, manufacturing, automotive to oil and gas where he has led improvement deployments across multiple regions and countries.

Sample projects

Oil Sands – Managed Lean Deployment across 7000 person site delivering multiple Kaizen events across every department. Built internal capability in each department to allow them to sustain the gains. Benefits included $100’s million in both cost reduction and revenue generation.

Supply Chain Programs – Gary led supply chain programs covering all aspects of purchase to pay. Resulting in warehouse rental costs reduction of £1.5m, cost reduction of over £10m, stock reduction of over £20m while addressing root causes, putting in place sustainable processes to prevent re-occurrence.

Safety Improvements – Multiple projects that look at many aspects of safety within the workplace and workforce. These include workplace organisation using 5S, which also reduced costs by £450k on rental. Incident investigations improvements, that showed 60% improvement in quality of investigations. Fatigue management of the offshore workers, resulting in approval of the first offshore study on new working patterns to be funded.

Areas of expertise

  • Leadership training
  • Executive coaching
  • Lean programme deployment
  • Lean / Six Sigma
  • Agile deployment
  • Visual management
  • Value stream mapping
  • Execution of kaizen events
  • Leading international teams

Key areas of focus

Lean and Agile deployment – proven track record of deploying improvement approaches multiple regions, sites and departments.

Leadership Coaching– working closely with senior leaders and their teams to help them understand their roles in any transformation to assist in the embracing of change within organisations.

Sustainable Delivery – experienced  in building internal capability within companies. Developed a unique approach to the replication of improvements, across departments, sites and geographical boundaries.

Get in touch with us today sales@pbi-ltd.co.uk

Callum Taylor
Continuous Improvement Coach

Personal profile

Callum is a Chartered Mechanical Engineer, experienced Lean Coach, Scrum Master and Lean Six Sigma Black Belt. Callum has driven sustainable change and agile transformation  through all levels of large corporate  organisations and small fast paced companies. He has the flexibility, leadership skills and social awareness to galvanise and drive teams from the shop floor to the boardroom.  Callum has a proven track record in many different industries including, oil and gas, aerospace, automotive, fabrication,  machining, paints and treatments, in both the office and the shop floor.

Sample projects

Automotive manufacturing – Lean transformation programme: Kaizen Leader within a Lean transformation programme.  Improved on time in full of wire line truck manufacturing line from 48% to 83% and reducing over time spend by £750,000 a year. Performed through end to end value stream mapping, 5S, introduction of Kanban System and other visual management and standard work practices 

Oil & Gas Operation  –Facilitated program of kaizen events in service of reducing the number of indirect hours spent offshore. These includes in depth analysis of planned maintenance routine, asset control system and implementation of survey management system and digital tool to cut the number of personnel going offshore to perform survey cutting maintenance hours and surveys offshore by 50% saving over £5m

Aerospace Manufacturing – Reduced scrap rate of manufacturing line of Fuselage Frames  from 10% to 1% through through 8 step Practical Problem Solving to solve a chronic and complex problem saving over £500,000. This includes introduction of new and automated machinery, detail SOPs, design of experiment ,statistical process control, root cause analysis and error proofing.

Areas of expertise

  • Lean Methodologies
  • Visual Management
  • Value Stream Mapping
  • Execution of Kaizen Events
  • Scrum Master
  • Six Sigma 
  • Leading and managing teams 
  • Strong academic and technical understanding
  • Networking and relationship building 
  • Languages: English

Key areas of focus

Finance – Qualified Lean Trainer delivering training in the UK, Azerbaijan and Georgia to Regional Leadership Teams . 

Developed 3 tier training program creating autonomous CI, Agile methods and systems of working. Including and understanding of lean tools, manufacturing simulations, basic problem solving skills, advanced mentorship, facilitation and leadership skills.

Created and provided training program on 8 step Practical Problem Solving process and coaching pf trainees own projects. This includes two, one day training sessions and ongoing coaching and support.  

Engineering  – As a charted engineer Callum specialises in improvement in the engineering space. These airframe component milling mand matching, Subsea control system manufacture, truck building painting and facilitation.  This includes quality improvement, cost reduction and efficiency improvement utilising these who do the job. Using my experience as an engineer to lever the knowledge and expertise of the workforce within the design process.

Get in touch with us today sales@pbi-ltd.co.uk

Peter Stewart
Continuous Improvement Coach

Personal profile

Peter is a Continuous Improvement Manager, Leadership Coach and Coach with over 30 years’ experience of delivering Lean tools and leadership coaching in a range of business sectors. Peters early career was shaped by Toyota’s Automotive Supplier Development Team where he trained in Kaizen, Visual Management and the application of Lean Tools.  Having held senior C.I. & Operational roles within Automotive, Computer Manufacturing and Finance, Peter has accrued excellent operational management and general business skills to compliment his delivery of Lean and Agile methodologies.  Peter`s extensive experience ranges from coaching Multinational Leadership Teams and managing Continuous Improvement Teams to delivering Kaizen events and implementing Campaign Rooms at all levels within organisations. Experience and business judgement accrued over a significant period as a senior manager and business owner enable him to deliver end to end solutions in a balanced and practical manner in any operational environment.

Sample projects

Oil & Gas Upstream Global client– Project Based C.I. Coach: In supporting the Project, Peter implemented a Campaign Room which shaped the transition of the project from readiness to off-shore execution, conducted  Value Stream Mapping  and Kaizen Events, Installed and provided on-going coaching for Huddle Boards including HSE, planned a Perfect Day Workshop and provided on-going support for the Leadership Team. The project exceeded its goals on every front including: Finished 10 days earlier than base-line plan. Productivity exceeded plan executing 97K productive hours against a plan of 79k with an additional 19k hours delivered. Installed 3 Seawater Lift Pumps against a plan of 2 following the Kaizen event. Fully installed and commission the Gas Turbine against a very tight schedule and significantly, delivered safely with zero reportable safety incidents.6 weeks ahead of schedule

Computer Manufacturing– Leadership Coaching, Re-structuring, KPI Alignment & Lean Deployment: Deployed to US facility to manage immediate change. Delivered coaching to key stakeholders to obtain buy-in for cultural change. Facilitated organisational and shift restructuring to align for future delivery. Applied various Lean methodologies to establish areas of opportunity based on KPI impact. Delivered VSM, Kaizen events and Workshops to drive improvements. The key performance related deliverable was outgoing quality which was reduced from 2.20% to 0.02% within 9 weeks. The improvements delivered secured existing and future contracts, including major (USA) UPS contract.

Financial Sector Lead a customer facing review of product and service offering identifying  improvement areas. Used Lean & Agile methodologies to re-structure product and processes to deliver a marketable product at a competitive cost. Removed waste and stream-lined internal processes.

Computer Manufacturing– Introduced & Managed Lean Implementation: Undertaking a combined Operational and C.I. Management role, Peter facilitated the implementation of Lean within Hewlett Packard. The program included the facilitation of cross-functional and multi-national senior stakeholder buy-in. On-going coaching and education of key stakeholders to nurture the cultural change. Implementation of training programmes and on-going coaching for the C.I Team. The team delivered multiple events across all areas of manufacturing and engineering forming a new department within the global HP organisation.

Areas of expertise

  • Leadership mentoring and coaching
  • Strategic Lean Deployment expert
  • Management of C.I. Teams
  • Lean Methodologies & Agile ways of working
  • Visual Management
  • Implementation of War / Campaign Rooms
  • Value Stream Mapping
  • Kanban
  • Execution of Kaizen Events
  • Set-Up reduction expert
  • Project and Stakeholder management
  • Implementation of sustainable process improvement programmes, governance structures and KPI’s including performance tracking and benefit rationalisation

Key Areas of focus

Operational Management –  Experienced manager of C.I Teams in regional and cross-regional situations in both the physical and virtual environments. 

Transformation &  Leadership Coaching– Experienced  Leadership Coach, having delivered end to end organisational:

  • Re-structuring, KPI Alignment, Lean  and Agile deployment planning.
  • Coaching of key stakeholders to obtain buy-in for cultural change. 
  • Facilitating  organisational strategy & tactics to align for future delivery. 
  • Practical hands-on application of  Lean & Agile methodologies working with organisation to deliver results in short time-frames.

Practical Delivery – Always focused on delivering real-time, tangible results using  appropriate  tools.  Experienced in application of a wide range of Lean and Agile methodologies having recently  delivered:

  • Campaign Rooms: Execution planning and readiness through to operational phase
  • Set-up reduction of major activities in the off-shore environment
  • Ongoing mentoring and coaching of teams via Campaign Room’s and Huddles.

Get in touch with us today sales@pbi-ltd.co.uk

Susan Hay
Continuous Improvement Coach

Personal profile

Susan is MBA qualified with extensive experience in continual improvement, project and commercial initiatives.

Susan has delivered large Operational, Service and Project initiatives  with the focus on value add, on time delivery and sustainability, through applying Lean and Agile techniques and tools. She has executed improvements in the Electronics, Manufacturing and Service, Industry and in the Oil and Gas Industry, working with major companies such as BAE Systems, Selex, Thales, BP and Aker Solutions. Susan is an experienced Coach who utilises her project management skills to effectively deliver Agile Initiatives, focusing on Lean, risk, (opportunities and threats), and high performance through team integration and alignment.

Sample projects

Oil & Gas – Financial Decommissioning: Executed VSM to identify issues & constraints in global decommissioning costs estimation process. Reduced process to once annual, and execution of process from 3 months to 1 month. Reduction in time and manpower requirements by >50%, creating capacity to interrogate outputs, identify mitigations and increase quality of outputs.

Oil & Gas – Lean Project Execution: Led a global lean project execution management review. Applying VSM on current processes,  identified numerous improvement opportunities which were then executed as Kaizens. Improved Projects performance by: Contract growth through effective change management training & tools, >10% per project: Threat reduction & opportunity increase through Global visibility, actionability and prioritisation of risks, specifically supplier risks & mitigations, increasing project profitability: Reduced project control team headcount by 25%, by cross training, multiskilling personnel in a controlled manner through implementing competency management criteria & process.

Oil & Gas – Project Performance Room: Implemented  a cross functional visual Management Program room with scheduled meetings driving business alignment to customer needs, balanced workload, work levelling, setup reduction and increased customer focus throughout the business, driving functional performance accountability. Customer satisfaction through improved through OTD, increased by 14%, and effective accurate communication.

Work Management – Setup and coached to sustainability: Huddles to improve team communication, accountability and fast actioning: Workload visualisation and Kanban’s to drive focus, accountability and priorities whilst managing capacity:  Campaign rooms to reduce waste (time & effort) and introduce agile working, performance visibility and customer focus.

Areas of expertise

  • Team building, alignment, development and performance
  • Change Management
  • Application of Lean / Agile Frameworks to deliver improvements quickly and sustainably 
  • Coaching
  • Oil & Gas Programme and project management 
  • Commercial and contract negotiation
  • Establishing sustainable process performance  governance structures including ownership, KPIs, controls and benefits tracking
  • Customer Relationship Management, Stakeholder Management
  • Finance & Commercial (Controlling, Reporting, Risk, Change, Contracts)
  • Reservoir Development
  • EPC Project execution & control (Planning, KPI’s, Teams)
  • Maintenance & Service

Key Areas of focus

Electronics Service Industry – Outsourcing: Commercial Leader and Implementation Manager for outsourcing 30 people plus £2M of assets from a military vendor, BAE Systems, to a commercial electronics service provider Aeroflex. Including the physical relocation, integration into an established business and training on operational system and processes of 30 people, promotion of the additional capabilities and capacity to new and existing customers. Performed through Value Stream Mapping, Kaizen, Visual Management and 5S. Enabling originating company focus on core business and receiving company expanded service portfolio and extensive secure growth, >28% revenue growth. 

Electronics Service Industry – Asset Management: Led an asset management programme with data analysis, auditing, unique identifying and transfer of over 5000 test equipment assets to new ownership through planned Kaizen & 5S events over various UK locations for 2 major companies. Including: implementation of an IT online equipment management system enabling JIT asset management: development of a commercial model for test equipment self-sustainment and capital investment. Through analysis and implementation: reduced inventory holding by >20%, creating savings in maintenance and storage: increase utilisation: reduction in capital spend.

Get in touch with us today sales@pbi-ltd.co.uk

Derek Smith
Continuous Improvement Coach

Personal profile

Derek is a certified Lean Six Sigma Master Black Belt, Kaizen Facilitator and Lean/Six Sigma Trainer, with 2 decades of operational excellence and business leadership experience. He has worked in diverse environments and cultures, extensively along transactional and physical E2E value chains. He has delivered transformational projects and led international teams across upstream and downstream, and offshore service/manufacturing in the energy sector. His portfolio of companies includes BP, Shell, GE and ABB.

Derek leads with skin-in-the-game, whether directly or leading teams to deliver fast, tangible and sustainable results. He is a rapid, effective problem solver and strategic thinker, utilising broad industry knowledge, real world experience and nuanced commercial acumen.

He is currently working with an Oil & Gas Operator in the Middle East, deploying Lean into the business and leading large scale Kaizen events.

Sample projects

Oil & Gas Downstream – Continuous Improvement Transformation Programme Leader for Terminal Safety and Operational Performance across South East Asia and Middle East for an Oil & Gas major.  The approach included operational and behavioural diagnostics, terminal go-sees, lean application, replication of best-practices, and development of terminal staff Continuous Improvement capability. The project delivered a substantial change in safety and performance culture, with measurable improvements in terminal KPIs across the region. Multi-million dollar optionality given to Traders as a result of enhanced terminal throughput capacity.

Oil & Gas Upstream – Delivered a 6 to 4 reduction in Platform Supply Vessels (PSV) serving North Sea installations with no impact on service quality. This was achieved through Kaizen methods applied to beach operations, installation operations and route optimisation. The outcome was paired with opportunistic contractual negotiations to deliver 14M GBP budgetary benefits.

Oil & Gas Shipping – Forensic analysis of refinery shift patterns delivered to CEO / Board of an Oil & Gas Operator and Government authorities. The work yielded statistically significant anomalies and subsequent loss prevention improvements.

Renewable Energy – Project Lead in a strategic and tactical optimisation initiative for global end-to-end power generation processes in renewable energies, specifically for wind, solar and storage. The project focused on the translation of Oil & Gas deal making processes to the new energy sector. This required new commercial and dynamic interpretations of processes set up for more traditional deal structuring and progression. Success required detailed process analysis via a series of improvement workshops combined with commercially sensible efficiency options, as well as resolving divergent stakeholder options born from diverse backgrounds and experience.

Areas of expertise

  • Lean programme deployment
  • Lean / Six Sigma
  • Statistics and data analysis
  • Visual management
  • Value stream mapping
  • Daily huddles and campaign rooms
  • Execution of Kaizen events
  • Leading international teams
  • Stakeholder collaboration
  • Training and coaching, shop floor to C-suite
  • Commercial acumen

Key areas of focus

Lean / CI Deployment – proven capability to deploy Lean / Continuous Improvement (CI) at scale. Example: led the deployment across South East Asia and Middle East for the Supply & Distribution sector of an Oil & Gas major. Yielded >$150M in bottom / top line benefits for the organisation over a 3 year period while growing a diverse team of CI experts across the region. By the end of the assignment, achieved step change cultural and capability shifts in the organisation.

Content Creation – track record of developing training and skills development programmes in Lean / Six Sigma / Operational Excellence, at both local and global level. Example: co-created Kaizen Event Facilitator for a global company.

Data Driven Improvements – highly developed analytical capabilities delivering practical insights at programme and project level.

Get in touch with us today sales@pbi-ltd.co.uk

Eddie Martin
Continuous Improvement Coach

Personal profile

Eddie is a certified Kaizen Facilitator and Lean Six Sigma, Black Belt. He also has a Masters Degree in Quality Management specialising in using lean tools.  Eddie has a number of years working within senior management teams and has ran his own businesses for over 20 years.  He has a very hands on approach and over the years has gained a lot of experience in using a number of Lean / Agile tools.

Eddie is also currently studying for a distance learning  MBA at Strathclyde University Business School, looking specifically at how Lean and Agile tools can be used to drive business strategy.

Sample projects

Oil & Gas Upstream – Lean transformation programme: Kaizen Leader within a Lean transformation programme. Facilitated a new cross functional team looking at effective headcount / resource usage.  To date 1500 days returned to the business.  ICSS – Process / headount review on 2 North Sea assets resulting in an annual saving of $2.5M.  Survey elimination – reducing the amount of time spent offshore carrying out physical surveys of plant by using digital data – $2M reduction in costs annually.  

High Volume Manufacturing – (Electronics) – worked on a number of projects looking at streamlining manufacturing techniques and managing waste in a high volume, highly complex environment.  Eddie worked on a project which managed production line changes / turnarounds.  This went from one product change per day to allowing a product change per hour on all production lines.  Using various lean techniques including Kanban, set-up reduction and Kaizen.

 Waste Reduction- Eddie has worked in many waste identification, reduction, elimination projects within the manufacturing sector.  Using process mapping / VSM to identify areas where waste is generated, the causes of waste and the potential opportunities to eliminate the causes of waste.

Areas of expertise

  • Lean Methodologies
  • Visual Management
  • Value Stream Mapping
  • Execution of Kaizen Events
  • Project management
  • People management / Leadership
  • Vendor management and contract negotiation
  • Stakeholder management
  • Developing Strategy
  • Establishing sustainable process performance  governance structures including ownership, KPIs, controls and benefits tracking
  • Languages: English

Key areas of focus

Business Transformation – Lean transformation programme: Using lean / agile methodologies in changing the way how businesses are run.  Matching key business deliverables (KPI’s) into every aspect of the business.  Using lean / agile techniques to enhance the day to day running of business.  Working closely with leadership (sponsors) to drive consistent and coherent messages throughout the organisation.

One team / Culture Change – providing business leadership with the tools that best serves communication throughout the different layers.  Using effective sponsorship techniques to ensure that everyone in the business from the top down knows the goals of the business and has the tools at their disposal to achieve them.

Get in touch with us today sales@pbi-ltd.co.uk

Gerry Grattan
Continuous Improvement Coach

Personal profile

Gerry is a certified Kaizen Facilitator, Lean Six Sigma Master Black Belt,  certified Scrum Master and Product Owner. He is hands on and brings a practical fast-paced cadence to different types of Transformation and Innovation programmes.

He is an E2E improvement expert and trusted advisor with significant project, programme and change management experience. Adept at leading large transformations with the focus on business performance, generating ownership and building internal capability through upskilling of staff.  He has delivered outcomes in major oil and gas companies across production sites, financial operations, logistics and IT.  He has diversified his experience by incorporating learnings from the Social Enterprise sector and advocates for a Purpose-Led approach to business improvement and delivery.

Sample projects

Oil & Gas/Mining– Lean transformation multi-year programme: Lean Coach to a 250k bbl/day production site.  Conducted end-to-end Value Stream analysis  and facilitated over 20 critical improvement projects aimed at delivering reliable high yield production from day to day Mining operations. Trusted advisor to the Leadership Team, establishing pipeline of improvement opportunities, upskilling of Kaizen Facilitators and implementing War Room visual management for E2E production site.  Transformation projects used various Lean techniques, including VSM, 5S, FMEA, SMED & Poke-Yoke.  Site improved operational performance from under 175k bbls/day to 250k bbls/day.  Delivered Lean training and coached client site staff.

Circular Supply Chain – Led mission-critical innovation project to establish a network of circular economy partners across the UK.  The network diverted 200k m2 of flooring from landfill disposal, built reuse and repurpose product lines and delivered a positive P&L outcome for the main client.  After delivering the network, built a portfolio of circular economy growth opportunities across the EU region  for the client’s core innovation team to manage in the following 3 years.

Tech4Good  – Product Owner for technology for good provider to the Third Sector.  Led initiative that took the next product feature from initial ideation through roadmap design with the outcome of a fully built backlog of work to be pulled by the DevOps team.  Trusted advisor to the founders helping them to build out portfolio of opportunities for the medium term.

Areas of expertise

  • Lean methodologies and mindset
  • Agile ways of working
  • Scrum framework
  • Startup culture in large organisations
  • Digital transformation
  • Upskilling of others through training and coaching
  • Executive and leadership coaching
  • Design and facilitation of workshops
  • Co2 reduction and positive environmental impact
  • Purpose-led positive social impact

Key areas of focus

Transformation – Has experience of being a Coach, Trusted Advisor and a Lead within different types of transformation.  Hands-on practical experience of being part of transformations focused on:

  • Cost Leadership to deliver overall $640m reduction in operating costs so that unit price was competitive when market prices were low. 
  • Lean/Agile Transformation to generate $1bn of cashflow from operations. 
  • Digital Transformation of a global IT function within large corporate organisation.  

Inhouse Capability – Lean Master to Oil & Gas Joint Venture. Helped leadership team uncover a gap in the JV’s culture in relation to Performance and Problem Solving.  Established a multi-year program to build a critical mass of internal skilled problem solvers across the key business performance Value Streams.  Trained, coached and upskilled 200+ staff on offshore production assets and within central onshore sites to practitioner level in Lean methodologies and mindset.  Established a Lean Manager/Leader program to help senior leadership down to front line leaders become more effective at fostering Lean mindset.

Get in touch with us today sales@pbi-ltd.co.uk

Steven Troman
Continuous Improvement Coach

Personal profile

Steven Troman is a Continuous Improvement Manager, Leadership Coach and Coach with over 30 years’ experience of delivering Lean tools and leadership coaching in a range of business sectors. Steven worked in 1st tier automotive  before 10 years with Toyota gaining a deep insight into TPS at both a technical and behavioural . He worked across  Production Planning & Control, Engineering & Project Management

He then moved into a consulting role deploying Lean approaches into a range of industries including Banking, Insurance, Operations and Public Sector. He returned to operational role within the Aerospace industry taking leadership roles in Continuous Improvement and Supplier Development. Equally comfortable shaping strategy or delivering shop floor operational improvements. He is a passionate believer in delivering business performance through the active engagement of all staff.

Sample projects

Public Finance– Supported the roll out of an enterprise wide lean transformation in a range of divisions. Training & subsequently coaching client internal consultants in lean philosophy. Supported a structured diagnostic and intervention approach to deliver circa 20% productivity improvements.

Led a pilot Lean approach within a European tax authority to drive performance improvement through a lean culture change programme.

Beverage Manufacturing – Led a team of 15 business leaders from all parts of a blue chip global supply chain to develop and pilot deliver a Lean operating system.  Building the lean knowledge in the organisation to develop lean leaders to support the roll-out of the approach across the business.

Financial Sector–  Led the deployment of a lean operating model across the USA within the underwriting function of a major global insurer. Also targeted Collections & Receivables management within the same group to increase cash flow and increase underwriting capacity

Aerospace – As part of a government funded scheme aimed at developing the capability of the UK aerospace supply chain to drive. Led a team of 14 experts in Operational Excellence, Engineering, Business Development, Finance to deliver tailored interventions in 7 SME’ s to drive their growth resulting in a doubling of their growth against their industry peers.

Aerospace – Supported development of a Lean Operating system within a supply chain unit of major aerospace organisation to accelerate of business performance to cope with rapid sector growth

Automotive –  Project Managed over delivery of business critical production and  supply chain control system with zero disruption to ongoing production output.

Automotive – Project managed a £50M plant simplification project to give increased manufacturing flexibility to allow greater and more rapid reaction to market and customer demand conditions

Areas of expertise

  • Lean Leadership Development
  • Lean Programme Deployment expert
  • Delivering results through CI team managing
  • Lean Methodologies & Agile ways of working
  • Project Management
  • Value Stream Mapping
  • Kaizen philosophy
  • Extensive detailed lean tools knowledge and deployment
  • Coaching in deployment of lean tools
  • Six-Sigma
  • Agile –Lean Methodology integration

Key areas of focus

Operations Management – experienced manager of C.I Teams in national and international situations. Having performed CI and executive roles understands  the challenges from  both sides  and can navigate the conflicting demands.

Organisation Transformation – experienced  in developing & delivering change in operating systems  and culture to deliver business objectives.

  • Developing organisational vision and strategy.
  • Aligning organisation behind this vision through effective policy deployment.
  • Driving delivery of the vision through active support at all levels of the organisation.

Employment  Engagement – always focused on utilising the fully human capital of an organisation. Developing an environment where all staff understand their role in delivering the organisational vision. Delivers sustainable organisational capability development through structured coaching approach.

Get in touch with us today sales@pbi-ltd.co.uk

Ian Memmott
Continuous Improvement Coach

Personal profile

Ian has over 25 years experience of leading Lean deployments and Continuous Improvement programmes in a wide range of operational environments, covering both manufacturing and transactional. Typically operating within a management team  and latterly as a consultant, he has successfully implemented lean activities in oil and gas, aerospace, first tier automotive and  FMCG. Employing a pragmatic approach to problem solving, he particularly enjoys the focus and intensity that comes with factory turnaround projects.  He has also held operational management roles in quality, production engineering, manufacturing and maintenance. Originally qualified as a Chartered Engineer Metallurgist, Ian worked in defence and power generation prior to following the Continuous Improvement route. He also enjoys developing and mentoring teams and played a significant role in facilitating a cultural change programme in a major blue chip aerospace company.

Sample projects

Oil & Gas Upstream – Led two consecutive VSM and Kaizen activities to improve work management, procurement and supply of Pressure Safety Valves in two different regions – North Sea and then Azerbaijan, Georgia and Turkey. Through the introduction of new standard working procedures and improved materials management controls, the projects delivered  $5m of avoided cost and approx 40,000 hours saved to the business

Aerospace – as  part of a team brought in to turnaround a failing manufacturing facility following a venture capital buy out, Ian formed and led the Cost of Poor  Quality team. Coaching the team to employ a very structured  approach to problem solving, manufacturing scrap was reduced by 70% in under 6 months – saving £2.4m/annum. Ian then went on to successfully manage a complex quality issue with a major US supplier that had the potential to stop all Airbus wing production.

FMCG  – as a Consultant, Ian led the site Lean deployment for a Spanish company new to UK, supplying a range of biscuits and cereal bars to a major supermarket. He devised and delivered a training and mentoring programme to a selected in-house team of Lean Practitioners.  Using a combination of lean techniques, including Line Balancing, TPM and SMED, the output was doubled and the waste halved whilst significantly reducing headcount.

Aerospace/Oil and Gas – Led “Contracts Factory” project which applied lean tools and techniques in a Supply Chain Unit sourcing team. The project doubled supplier contract signature rate and returned savings of over £10m/annum. Then some years later, applied a similar approach in a major oil and gas company to reduce contract sign off lead time by half, resulting in savings of $6m/annum.

Areas of expertise

  • Strategic Lean Deployment
  • Lean Six Sigma Black Belt and Programme Manager
  • Leadership mentoring and coaching
  • Visual Management
  • Value Stream Mapping
  • Execution of Kaizen Events
  • Set-Up reduction
  • Total Productive Maintenance (TPM)
  • Implementation of OEE management systems
  • Optimising cell design (line balancing /JIT pull/Kanban)
  • Workplace organisation of shop floor and offices (5S)

Key areas of focus

Lean Deployment and Focussed Improvement Delivery:

  • Track record of developing tailored Lean Deployments across a range of industries through the training and application of Lean techniques
  • Pragmatic common sense approach to the application of Lean & Agile methodologies in order to deliver results.
  • Coaching of key stakeholders to obtain buy-in for cultural change.
  • Implementation of Campaign Rooms through the use of structured KPIs and robust short interval control
  • Experienced Lean Six Sigma practitioner, data driven and focused problem solver
  • No nonsense approach to factory turnarounds

Get in touch with us today sales@pbi-ltd.co.uk

Alan Todd
Continuous Improvement Coach

Personal profile

Alan is a certified Kaizen Facilitator and Lean Six Sigma Black Belt and holds a Masters Degree in  International Relations. He is  hands on and has actively delivered Kaizen Events at all business levels .

He is solution focused with the ability to balance customer requirements against business needs.  Alan has significant project and programme management experience, leading large operational and IT transformation engagements with the focus on sustainability of process performance, and ownership. He has delivered projects in major international government organisations, oil and gas companies, construction, mining and the automotive industry.

Sample projects

Mining – Lean transformation programme. Kaizen Leader within a Lean transformation programme. Conducted end-to-end process analysis using Value Stream Maps and delivered improvement projects in 11 countries in Africa. Engaged with senior stakeholders to obtain buy-in to deliver these projects.
Led process improvement workshops using various Lean techniques, including SIPOC, 5S, FMEA, SMED & Poke-Yoke. Spearheaded a unique component rebuild centre in Tanzania. Delivered training to local staff in logistics management to increase internal capabilities. 

Oil & Gas  Facilitated regional engineering team Value Stream Map and Kaizen event to reduce waiting time and increase delivery of technical documentation to partners, creating quality through increased options. This led to a cost avoidance of 36M GBP a reduction in document lead time from 175 days to 30 and an increase in delivery of product from 6 per year to a projected rate of 21. This included collaborative working with clients in the Kaizen process. Managed program setup, full project life cycle management, best practices and dashboards development, interventions, and liaising with stakeholders in a highly complex environment

Automotive – Project delivery improvement. Led a project to modernise a state automotive operation in central europe. This was critical to national development and included the integration of local and external  technology and staff . Deployed best practices and visual management to maintain improvements.

Areas of expertise

  • Lean Methodologies
  • Visual Management
  • Value Stream Mapping
  • Execution of Kaizen Events
  • Finance Programme and project management
  • Vendor management
  • Stakeholder management
  • Establishing sustainable process performance  governance structures including ownership, KPIs, controls and benefits tracking
  • Languages: English

Key areas of focus

Cultural Transformation and Growth – Created transformation programmes within business and governmental environments. This often would include coaching leaders to become champions and change agents within their organisation. 

He has worked at all levels to create and support transformation, guiding organisations on their transformation, including the creation of internal capability from  “zero knowledge” base.

Energy– Alan has worked extensively in the energy sector at a global level  including oil and gas, mining and power generation. Working at all levels he is happy to work hands on and is also comfortable alongside business leaders.  

He comes with a demonstrable record in leading and mentoring in agile and lean methodology across at all levels in the industry supporting strategic objectives, operations and change management.

Get in touch with us today sales@pbi-ltd.co.uk

Nikita Korolev
Continuous Improvement Coach

Personal profile

Nikita is an International Relations graduate with extensive experience in industries, such as retail, nuclear energy, petrochemicals, oil & gas. He has delivered Lean projects across multiple functions in energy sector. Nikita has been actively involved in Continuous Improvements since 2012, his portfolio of companies includes Rusatom Service, Sibur, BP.

Nikita is a hardworking and ambitious individual with excellent communication skills that enables him to effectively engage with all levels within organizations and promote Lean culture. A sound knowledge of three languages allows Nikita to work with people from diverse environments and cultures in delivering results.

Projects

Oil & Gas Industry Operation – As an Agility Coach implemented different forms of visual management across multiple teams for BP Azerbaijan. Supported and developed teams using huddle boards, stand ups, campaign rooms. Implementation of visual management allowed 10 teams to execute their day-to-day business activities faster and more efficient, provided data-driven conversations within teams, improved performance and team spirit.

Nuclear Industry Project Management – As a part of the renewal project team, focusing on safety, cost and timely delivery of projects in nuclear industry, Nikita participated in projects for the supply of spare parts for Russian design nuclear power plants in Bulgaria, Hungary and Slovakia. Implementation of process improvement tools and visual management techniques allowed the team to successfully manage the project on renewal of 3 nuclear plants.

Petrochemical Industry – Marketing & Sales Development As a member of strategic marketing team  Nikita conducted analysis of polyethylene customs statistics, the data obtained became the basis for the development of strategic goals of the company until 2025. 

Nikita analyzed the results of the student case-championship, applied Continuous Improvement approach, which allowed to identify new product solutions. As a part of marketing strategy team, he engaged with Chinese analytical agencies, thanks to Nikita’s work the company was able to obtain more accurate data on the Chinese polyolefin market and adjust price forecasts.

Areas of expertise

  • Lean Methodologies
  • Visual Management
  • Value Stream Mapping
  • Execution of Kaizen Events
  • Project Management
  • International Relations
  • International Economics in Oil & Gas Sector
  • Languages: English, Russian and German

Key areas of focus

Lean / CI Deployment supporting business using Lean tools (Value Stream Mapping, Kaizen events, workshops) for improving processes and performance of business units. Example: co-facilitated Value Stream mapping sessions on “as is” processes for Procurement & Supply Management Team and Projects Team.

Remote Working Solutions Development – developing and creating  Lean / CI training materials and courses for remote working, adjusting Lean methodologies for remote working environment. Example: co-created Standard Operating Procedure for remote VSM and Kaizen events, adjusted visual management techniques for remote usage.

Get in touch with us today sales@pbi-ltd.co.uk

Anthony Babes
Continuous Improvement Coach

Personal profile

Tony is a junior Lean Consultant. He is hands on and has been an active part of Kaizen events. He has a background in site carpentry which helps him gain ‘buy in’ from employees on the floor. In his previous role he was a working foreman for a small house building firm, meaning he was incharge of planning  other trades and materials for jobs to make sure they kept to schedules and deadlines. He is an strong team player and understands the importance  of utilising  the strengths of individuals  within a team to get the best outcome.

Areas of expertise

  • Lean Methodologies
  • Visual Management
  • Value Stream Mapping
  • SVQ2  in Carpentry 
  • Creative mind / practical outlook

Get in touch with us today sales@pbi-ltd.co.uk

Natalia Downs
Office Manager

Personal profile

Natalia oversees the administrative and financial activities that facilitate the smooth running of our organisation. She is experienced in all aspects of operating a business, as well as meeting customers’, suppliers’ and the team’s needs and expectations. She holds a Master’s Degree in International Human Resource Management. Her degree research focused on the role of Human Resource Management in successful Implementation of Lean and the positive impact of employee involvement in Continuous Improvement on the organisational performance.

Sample projects

Natalia took part in the development of our virtual training courses and currently oversees the training and development of our administrative team and the apprentices.

Areas of expertise

  • Human Resource Management and Lean Implementation
  • Employee Relations, Training and Development
  • Financial Management of SME
  • Xero Accounting Software
  • Office Management 
  • Work Planning using Lean Framework
  • Virtual Ways of Working
  • Development of Virtual Training Courses
  • Delivering Exceptional Customer Service
  • Languages: English, Russian

Key areas of focus

Retail and Hospitality – During her early career in the Retail and Hospitality Industries, Natalia developed strong communication skills in customer and supplier interactions. She worked as part of the Resort Sales and Reservations Team delivering training in up-selling and scheduling of the Spa and Leisure Club services in order to increase the Revenue and Customer Satisfaction. As a result of this Continuous Improvement Project, the Spa and Leisure Club turnover increased by £400K.

Natalia is very passionate about helping create the culture of trust, support and collaboration within our team and working towards growing Practical Business Improvements, while achieving effective and sustainable outcomes for all our clients.

Get in touch with us today sales@pbi-ltd.co.uk

Ashleigh Downs
Accounts Administrator

Personal profile

Ashleigh is currently a student and has just gained her Degree in Accounting and is now studying towards her Honors Degree. She previously worked in the Hospitality industry and had many different roles ranging from a waitress, to a kitchen manager and a chef. This previous experience has helped her gain extensive knowledge in working within and managing a team. She understands the importance of teamwork and  by being able to work with others and realise their strengths it brings out the best in them. She firmly believes that  people are a business’s greatest asset so if they are appreciated and utilized correctly then it leads to success.

Areas of expertise

  • Degree in Accounting 
  • HNC Hospitality Management
  • Accounting software 
  • IT programmes 
  • Research skills 
  • Clerical duties 
  • Organizational skills 
  • Communication and interpersonal skills 

Key areas of focus

Finance Alongside University Ashleigh is currently expanding her knowledge and is undertaking a Payroll course and a Xero course which will make her certified in both areas. This will help her to become more involved with PBI’s finances and let PBI utilize her in the necessary areas.

Get in touch with us today sales@pbi-ltd.co.uk

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