Modified and revised CV as of 01.03.2016

1. David Ian Booth
2, Buttery’s Court, 46a Normandy Street, Alton, Hampshire GU34 1DE England.
01420 362378 / 07946 021120. mutterley@outlook.com.
**www.linkedin.com/in/mutterley**
CORE COMPETENCIES & SPHERES OF SPECIALISATION.
 I have a 30 year career in Production/Manufacturing/Method Change across a
wide range of varied projects, processes, materials and finished goods. This
included (but was not limited to) Decorative and Vehicle Paints, Chemicals,
Cosmetics, FMCG Food & Beverage, Cigarettes, Dairy, Mineral Water,
Packaging (corrugated, blow and injection moulded) Household Aerosol
Insecticides, Biscuits and basic Pharmaceuticals.
 As a principled ‘hands on’ manager I work effectively from the ‘factory floor’
to ensure and encourage employee motivation, empowerment, acceptance of
responsibility and succession planning.
 I have a 6SIGMA BLACK BELT and qualifications in other ‘change
methodologies’ including CI, LEAN, KPI’s & Kanban, MUDA, Kaizen, 5S,
GEMBA, JIT, OEE & TPM/TPS/TQM. I have successfully implemented all
such methodologies- my CV has specific numeric details of many examples.
 I have lead project assessment, costing and subsequent equipment
procurement and factory commissioning. Analysis of processes and costs of
manufacturing.
 I have a long standing practice that in order to maximise all components of
the ‘manufacturing/production’ processes these areas need to be
continuously monitored/amended in line with ‘defined’ P+L expectations and
to enable identification and removal of non-added value costs & waste
reduction across all areas (combined with the application of CI/Lean) from
Directors/Senior Management downwards- all being essential components in
the reduction of overheads which combined with ‘factory savings’ are directly
aligned to the profitability of the business.
 Autonomous responsibility for ‘stakeholder engagement’ at all levels. Acting
as the ‘face’ of the business to suppliers, customers, the HSE, Local
Authorities including emergency services if appropriate.
 My experience shows that the ultimate ‘outcome’ of
change/implementation/analysis in ‘simple’ form sets goals of OTIF 99.5%
minimum, 0% equipment ‘downtime’, Right First Time 99.5% minimum,
0.5% returned ‘faulty’ goods and 0% reportable H&S incidents. Benefit is
also achieved by creating a ‘happy working environment’.
 I am a ’staunch’ advocate all HS&E requirements in any given
manufacturing/production situation(s) from basic gloves to special PPE. I
have NEBOSH & IOSH certificates which enable me to teach compliance with
ISO14001 & OHSAS 18001.
 I facilitate ‘identification, risk assessment & COSHH’ covering IMCO,
COMAHH Storage Facilities, REACH, DSEAR, ATEX & GHS.
 I established QC for raw materials & finished goods, accurate record keeping,
identification & action to reduce/remove sub-standard materials before use,
‘quarantine’ where appropriate and coding & traceability for finished goods.
 SUPPLY CHAIN –proficient and accredited in the use of SAP, ERP/MRP.
Extensive experience in ‘sales based analysis’ to set up raw material
purchasing systems aligned to Sales and Production Planning to ensure 0%
‘out of stock’ and ‘0% ‘overstock’. Monitor key raw material commodities
to be ‘ahead of the game’ in case of market shortages/price fluctuations.
1

2. March 2015 to September 2015.
MANUFACTURER OF LIQUID ‘HOUSEHOLD’ CONSUMABLES.
 Appointed as Senior Production Manager to ‘manage’ from the factory floor
60+ employees involved in the production, filling and packaging of a wide
variety of different products in varied pack sizes.
 The business was in private ownership until mid-2014 when it was acquired
by a larger Company operating from the North of England in a similar type of
product range and client base.
 The ‘takeover’ was not met with a positive response by the factory employees
and this had created a very significant backlog of orders, failure to achieve
more than a 60% order completion/delivery which had a ‘knock on’ effect with
customers being unable to support their own client base with product.
 I established very quickly that despite having 100+ active accounts, 2 prime
clients accounted for >50% of the £4M p.a turnover.
 An initial assessment of the ‘backlog’ showed that up to 90% of manufactured
products were in an ‘out of stock’ position either by quantity available being
less than on order or pack sizes available not being what was on order(s).
 A recent stock check was also reviewed and missing materials ordered whilst
the ‘principal’ raw materials (used in a high % of formulations) were put on a
‘regular’ order with suppliers.
 After prioritising orders and combining ‘like’ formulations that covered multiple
customers but with varied pack sizes/labels instructions to manufacture were
issued. I spent considerable time on the factory floor monitoring activity to
identify areas requiring urgent action by CI, waste reduction, improved
process times and H&S. Where possible, ‘changes’ were implemented
immediately. Factual ‘production planning’ was used to facilitate OTIF as the
‘norm’. Quality Control restructured to be effective at ‘problem pick up’.
 The role is ongoing and I have established new procedures to improve the
multiple areas requiring complete change. It will also take up to 2 months to
catch up on ‘old orders’ ensuring new orders are assimilated with them. There
also remain numerous ongoing problems including supply chain, H&S,
environmental and risk assessment, fire control for hazardous raw materials
and clarification/modification of existing MSDS to put them in line with newer
legislation and other EU requirements on labelling.
March-September 2014.
DWC LIMITED. (March 2014- August 2014). MANUFACTURER OF ‘WAX’
CONSUMABLES/SPECIALITIES.
CONSULTANT to the Managing Director/Owner on 6 month contract.
• Remit – carry out detailed ‘all area’ assessment of 2 sites – Productivity,
Process, H&SE, QC/QA, Supply Chain, Production Planning, Employee
empowerment, Hazchem/COMAHH, & ATEX Zoning.
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3. • Implementation of 6Sigma -Continuous Improvement/Lean
Manufacturing. Output improved by 17%. Waste reduced to 1%.
• Supply Chain modified to be ‘end to end’ and entered on SAP.
• 5S changes contributing to an 11% improvement on previous downtime.
• OTIF improved from 66% to 97%. Direct positive impact upon increased
profitability. Employee engagement and H&SE awareness improved in
all areas. Stakeholder/customer satisfaction increased significantly.
.
2010-2013.THE OPEN UNIVERSITY- MATURE STUDENT.
Bachelor of Laws (2:1) Degree LLB (OU)
Spent an unplanned 2 years in hospital for successful major reconstructive surgery
on my spine after a motorbike crash. Dedicated time to complete a LAW DEGREE in
the belief of its comprehensive benefits in MANUFACTURING - in areas ranging from
Employee Grievance to complex Contract Negotiation within the Supply Chain
function(s) - ‘terms of procurement’, ‘contracts of Sale for Finished Goods, ‘liabilities
and terms of business’.
1998-2010. FUTURCHEM INDUSTRIES LIMITED.MANUFACTURER OF
PATENTED ‘SAFE’ SOLVENTS.
General Manager/Co-owner. Prospect Works, Allerton Road, Bradford,
England.
 All products ‘formulated’ for specific applications in ‘SURFACE
PREPARATION’ and to provide a range of ‘qualities’ and ‘solutions’
requested by end users in OEM AUTOMOTIVE & AEROSPACE. Crucially
QC orientated therefore GMP enforced throughout. Considerable/service
‘tech support’ to end users.
 Product testing carried out ‘on line’ at the customer’s facility in ‘real time’
terms. Manufacturing involved new equipment specifications, in house
fabrication and innovative processes.
 With positive results both parties signed a ‘secrecy agreement’ covering the
’technology’ after which orders commenced. CI, 5S, LEAN & 6SIGMA-
implemented across all areas in support of rigid QC/QA.
 By year 7, gross turnover reached £7M- gross margin remaining stable at
73%. Employed 60 F/T and 30 P/T.
 A policy of working with the customer on Technical requirements generated
an excellent ‘customer focused business’ with unique patented products that
received multiple awards from the AUTOMOTIVE (MIRA) & METAL
FINISHING Industries.
 All products in a developing range represented unique & patented technology
with efficacy and safety not available in any other products. As a result of
these’ advantages’ it was possible to develop and supply ‘commercial’
products including Graffiti Remover, Oil Spill Remover, Patio & Driveway
Cleaner & General Purpose Cleaner Degreaser.
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4. 1992-1998. LONGULF TRADING. GLOBAL FMCG CONGLOMERATE.
SHIEKH A.A.S ANAM. Prince Albert House, Kingsmill Terrace, St Johns Wood,
London NW8.
Autonomous/Team role as Manufacturing and Production Manager/Consultant for all
project development, equipment and raw materials. Project assessment & costing,
procurement. On site for commissioning/start up and to ‘troubleshoot out’ problems.
Implement relevant systems and procedures including Continuous Improvement, 5S,
Lean Manufacturing, 6Sigma, Health & Safety, Environmental responsibilities and
detailed system(s) for all aspects of Quality Control.
Door to door/end-end documentation and traceability systems implemented as
standard across all areas of manufacturing starting with incoming materials. Many
varied Manufacturing Business’s with a base in Yemen and new factories being built
across the Middle East and the UK. Partnered my previous employers.
 New FMCG NON FOOD FACTORY x 3. SOAPS in Powder, Solid and Liquid
form. REVERSE OSMOSIS WATER TREATMENT PLANT PROVIDING >2M
LITRES/MONTH.
 New FMCG FOOD & BEVERAGE FACTORY x 3. Production of >50 product
types including Breads-loaves/stick/flat, Cakes, Biscuits, Snacks, Chocolate
bars (including KitKat, Mars, Snickers, Bounty and Milky Way).
Carbonated/Non carbonated drinks including Coca-Cola, Ginger Beer, Non
Alcoholic ‘Beer’, Fruit Juices & Flavoured Fruit Drinks, Mineral Water & Dairy
(see below).
 NEW BEVERAGE FACTORY. Tea Bagging from Leaf (Liptons License).
Coffee from Beans. Nuts & Dried Fruit Snacks.
 NEW FMCG DAIRY FACTORY- UHT Milk, Baby Milk Powders, Favoured
Milk Drinks, Yoghurt, Ready Made Custard, Jellies and other Dairy related
consumer goods.
 NEW FMCG CIGARETTE FACTORY. International brands under License
and local brands. Manufactured from Tobacco Leaf and included in house
printing of papers, inners and outer boxes. State of the Art facility. Full
automated including all packaging/palletising. Tobacco warehouse included
new technology ‘anti tobacco leaf bug infestation’ by computer operated air
spraying ‘insecticide/pesticide’. Production of >1M cartons/month with
expansion into local export markets (North Africa, Somalia, Eritrea).
 NEW PHARMACEUTICAL FACTORY. Paracetamol & Aspirin B.P
manufactured from powders. Syrups, Decongestants & Pastilles. Applied
GMP, BRC/FDA guidelines. Planned introduction of Vaccines and other
specialist medicines.
 SUPPLY CHAIN-Cradle to Grave set up from existing information. After 12
months started end-to-end SAP (MRP/ERP) computerised system. Utilised
the huge benefit of ‘group purchasing power’ to reduce material costs.
 Start of year 2 - material cost savings of 17% equating to US$16.8M and a
reduction in the number of suppliers by 21%.
 CI, LEAN, 5S, KPI – introduced into chilled, semi chilled & UHT milk factories.
4

5. Improvements of between 7%-15% in output.
 ‘Hands on’ leadership/management with 500+ local employees.
 NEW PACKAGING FACTORY-located as a ‘central hub’ on the site of the 11
‘consumer goods’ factories –production for in house use. Included Tetrapak,
Flowrap, Corrugated board/boxes/cartons, Printed Food Grade Foil, Injection
and blow moulding of bottles to rigid containers/Lids. Encapsulation & Blister
packaging for ‘pharmaceuticals. Tinplate conversion to ‘cans’.
 NEW AEROSOL Plant for INSECT KILLER- Flying & Crawling, Fragrances &
Body Sprays/Deodorants.-including WELCOME FOUNDATION License to
manufacture. 350,000 x 750ml per month output.
 2 years review - reduction in ‘GOODS RETURNED FAULTY’ due to
improved QC down from 19% to 4%. 5S DOWNTIME reduced from 13% to
3.4%. GROSS MARGINS increased from 11% to 27%. Raw material
savings of 4% equating to a US$13M p.a direct saving. Responsible for
manufacturing/production budgets and improvement to profitability and
extension of product ranges.
1982-1992. N.P.C.F. - ARAB REPUBLIC OF YEMEN.
CONGLOMERATE. SHIEKH A.A.S SHEIBANI.
 Appointed as MANUFACTURING, TECHNICAL & PURCHASING MANAGER
with a remit to develop and expand the production facilities for ‘PAINT &
CHEMICALS’ enabling capacity and processes for the introduction of new
products. New title – ‘FACTORY MANAGER’. 300+ local employees.
 Remit commenced with the preparation of a 5 year plan to enable ‘remit to
reality’.
 Introduction of a ‘SUPPLY CHAIN’ on a manual basis pending
computerisation of the business. Start of CONTINUOUS IMPROVEMENT.
 Example of new facility – local build of 500,000 Litres of Bulk Liquid Storage
to enable raw material cost savings of US$4M p.a, and full automation of
materials to production with pre set pumping system. Massive timesaving in
batch production quantified by the end of year 2 as 35% - enabled ‘spare
capacity’ to be taken up by the pre-planned introduction of a large new range
of products – lead to an increase in PRODUCTION of 70%.
 By early part of year 3 ACTUAL product types being manufactured and sold
increased from 46 to >300 and >500 by the start of year 5.
 Start of year 3 of plan- introduction of KPI’S and Kanban Cards.
Engineering/Maintenance started on 5S. 6SIGMA - the lead planning
mechanism. LEAN manufacturing and introduced successfully at the start of
year 4. QC/QA and ‘traceability’ systems put in place. Quarantine introduced.
 By the start of year 5 actual sales driven production increased from 246,000
litres (1983) to 2.2M litres (1988). Value of annual sales by year end of 1988
had increased by 985%.
 SECOND remit to establish manufacturing in a new factory commenced in
1985 under general heading of ‘PERSONAL CARE & HYGIENE’
PRODUCTS. Production commenced successfully with various Cosmetics,
Body Oils, Creams, Shampoos, Hair Colorants, Roll-on & pump action
Deodorants, Depilatory Creams, Medicated Creams, Sun blocks, Perfumes &
Fragrances.
 Further products were manufactured ‘under license’ from globally
recognisable market leaders. Factory under HACCP, GMP & BRC
5

6. Regulations/Guidelines at all times.
 THIRD remit in second new factory commenced in 1986 under heading of
‘Household Cleaners, Disinfectants and Clothes Whiteners/Stain
removers. Identical process followed as above including GMP, with
machinery and raw materials approved for immediate ordering.
 Attended training courses to gain greater knowledge in various areas and
specifically to ensure PPE was addressed to a standard relevant to the
hazardous nature of chemicals being used. Production commenced
successfully with Hard Surface Cleaners, Lavatory and Bathroom
Cleaners. Acid Descalers and Whiteners, Anti Bacterial Floor cleaner.
Bleach for Cleaning and Whitening of Cloth’s (large business sector across
the Middle East). First year production/double shift c280, 000 litres p.a.
Production increased to c420, 000 litres by end of 1988.
 In 1988 Group formed ‘alliance’ with another local large scale ‘business’ and
established multiple new FMCG state of the art factories located around a
central packaging plant that produced ALL of the various types of packaging
needed. Included printing. Full details as shown above under heading
‘LONGULF’.
EDUCATION & QUALIFICATIONS.
 ALLERTON GRANGE SCHOOL LEEDS, W.YORKSHIRE. 1972 -1978.
 ‘O’Levels Chemistry (A), History (A), Geography (B), English Lang (A),
Mathematics (B), Geology (B), Social Sciences (B), RE (B).
 ‘A’ Levels Chemistry (A), Geology (B), Geography (B).
 KITSON COLLEGE OF TECHNOLOGY, LEEDS, W.YOKSHIRE. 1978-1981.
 HND Mechanical Engineering. HND Organic Chemistry.
 OTHER QUALIFICATIONS.
 Law Degree – 2013 (2:1)
 6Sigma Black Belt – 1999. Continuous Improvement & Lean Manufacturing
Certificates & Annual Training Courses.
 NEBOSH Certificate – 1992.
 ‘Toyotarism’ courses attended- TPM/TQM/TPS – 1998.
 HACCP/ASEPTIC & CLEAN ROOM Certificate – 1985.
 Institute of Directors (London) Middle East Representative & Correspondent.
1982-1997.
 Paint Technology & Colour Pigments Certificate – 1980.
HOBBIES.
 Off Road motor biking and On Road Sports Biking.
 Fresh Water angling especially Carp & Pike.
 Dog Walking in coastal & local river areas.
 Open Sea Diving to PADI 3 – 100M.
NOTE: In October 2014- January 2015 I was in Florida, USA assisting my daughter
with relocation as a result of a promotion with her existing US/Global employer.
6

7. Regulations/Guidelines at all times.
 THIRD remit in second new factory commenced in 1986 under heading of
‘Household Cleaners, Disinfectants and Clothes Whiteners/Stain
removers. Identical process followed as above including GMP, with
machinery and raw materials approved for immediate ordering.
 Attended training courses to gain greater knowledge in various areas and
specifically to ensure PPE was addressed to a standard relevant to the
hazardous nature of chemicals being used. Production commenced
successfully with Hard Surface Cleaners, Lavatory and Bathroom
Cleaners. Acid Descalers and Whiteners, Anti Bacterial Floor cleaner.
Bleach for Cleaning and Whitening of Cloth’s (large business sector across
the Middle East). First year production/double shift c280, 000 litres p.a.
Production increased to c420, 000 litres by end of 1988.
 In 1988 Group formed ‘alliance’ with another local large scale ‘business’ and
established multiple new FMCG state of the art factories located around a
central packaging plant that produced ALL of the various types of packaging
needed. Included printing. Full details as shown above under heading
‘LONGULF’.
EDUCATION & QUALIFICATIONS.
 ALLERTON GRANGE SCHOOL LEEDS, W.YORKSHIRE. 1972 -1978.
 ‘O’Levels Chemistry (A), History (A), Geography (B), English Lang (A),
Mathematics (B), Geology (B), Social Sciences (B), RE (B).
 ‘A’ Levels Chemistry (A), Geology (B), Geography (B).
 KITSON COLLEGE OF TECHNOLOGY, LEEDS, W.YOKSHIRE. 1978-1981.
 HND Mechanical Engineering. HND Organic Chemistry.
 OTHER QUALIFICATIONS.
 Law Degree – 2013 (2:1)
 6Sigma Black Belt – 1999. Continuous Improvement & Lean Manufacturing
Certificates & Annual Training Courses.
 NEBOSH Certificate – 1992.
 ‘Toyotarism’ courses attended- TPM/TQM/TPS – 1998.
 HACCP/ASEPTIC & CLEAN ROOM Certificate – 1985.
 Institute of Directors (London) Middle East Representative & Correspondent.
1982-1997.
 Paint Technology & Colour Pigments Certificate – 1980.
HOBBIES.
 Off Road motor biking and On Road Sports Biking.
 Fresh Water angling especially Carp & Pike.
 Dog Walking in coastal & local river areas.
 Open Sea Diving to PADI 3 – 100M.
NOTE: In October 2014- January 2015 I was in Florida, USA assisting my daughter
with relocation as a result of a promotion with her existing US/Global employer.
6