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INTERIM PROGRAMME MANAGER – AMERICAN AIRLINES FIRST CLASS SEATING (BOEING 777-300ER),

ZODIAC SEATS UK LIMITED (FORMERLY CONTOUR AEROSPACE)

November 2012 - April 2013

I was responsible for delivering the hardware and entry into service (EIS) programme for a brand-new bespoke design for first class seating for American Airlines and their new fleet of Boeing 777’s. The following functional areas report directly to myself:


Supply chain (global subcontract management).

Quality.

Testing (full qualification).

Engineering & Design.

Configuration (drawings, ECR’s,5C’s, permits and concessions).

Production and manufacturing across two UK sites (OPS managers, quality, NPI engineers & build)

  • Surrey site supplied all structural composite components which were the foundation for suite build

  • South Wales site trims, manufacture components and final assembly of full aircraft suite

    • Manufacturing units (MU) – Supply completed metal parts

    • Main Site – Finally Assembly line


My main responsibilities and achievements were:


Continuous Improvement (CI).

Quality of composite parts which met business and customer expectations.

On time delivery, due to high contract Liquidated Damages (LD’s) per ship set.

Continual updating Product Quality documents for on the line inspection to help achieve 100% on time delivery and quality.

Introduction of TAKT time and supply chain feeding into the correct operation numbers on assembly line (defined flow process).

Main point of contact with customers (American Airlines & Boeing, liaising with both onsite and offsite representatives).

Re-organisation of project team to provide the ability to deliver under extremely tight timescales.

Global subcontract management.

Setting of budgets.

Increasing net profit yield by implementing “challenges” to functional areas.

Adjusting Financial reports so understood by business and not just finance.

Robust financial forecasting on monthly basis.

Aiding communication between sites and standardising the reporting methods.

Responsible for detailed planning for remainder programme.

Creation and perform weekly presentations (planning, forecast & progress) to company senior executives and customer senior executive’s.