Band 3 - Production Manager (Designer)

Location: London - 172 Buckingham Palace Road Victoria, 130 Bollo Lane Acton, Ruislip Depot.

As part of London Underground's Central Line Improvement Programme (CLIP), a project team comprising Transport for London's Fleet Renewals & Enhancement Fleet (R&E Fleet) department and London Underground's Train Modification Unit (TMU) will carry out modification works on 85 x 8-car Central Line trains and 5 x 4 car Waterloo and City line trains. These modification works will include:

AC Traction conversion

Train computer replacement

Saloon floor corrosion repair

Body end replacement

Accessibility modifications

LED lighting installation

CCTV installation.

Modification work will take 40 days for each 8-car train, and will be carried out in four locations

within the Acid Shed at Ruislip depot, within the existing AC10/AC15 buildings at Acton works, and a

new purpose-built modification facility AC14, also at Acton works.

This work has commenced, with prototyping ongoing in Ruislip depot and the first Production unit started in Acton. The programme will continue until 2023. There is a further aspiration to carry out heavy overhaul works alongside the CLIP programme so that each train need only be lifted once.

The holder of this post is responsible for integrating the various input information concerning the installation, testing and handover of trains between their initial acceptance from Fleet into Projects through to their hand back to Fleet in a modified state. The role holder shall ensure that the end-to-end plan for any one train going through CLIP is defined such that the works can be carried out safely, timely and to the required quality and acceptance standard. This is to ensure delivery of the project benefits.

As a Production Designer, you will be accountable to the Senior Project Manager for co-ordinating the efforts of numerous teams across London and out into the supply chain to bring together the information required to enable the production work. This will include incorporating lessons learned in response to any issue or process failure impacting on the successful delivery of vehicles required to meet the project programme.

You will be required to work across the CLIP team and with stakeholders including the labour supplier's engineering staff, Fleet maintenance staff, Trades Unions and representatives from across the supply chain. In doing this you must ensure that all work instructions are tailored to ensure a smooth, safe, assured, auditable, integrated production flow with suitable check points and quality interventions. Regular lessons learnt sessions will be carried out within the team and the role holder will ensure that these are captured in their output to ensure the production process is optimised and clear to all involved. Priorities include the reception of trains into the programme and their return to Fleet. Once these criteria are established the focus will move on to how the modification is done and how data in support of handover is captured and made into an auditable record.

Key Accountabilities

Understand and integrate the work instructions from a range of suppliers, ensuring that an end-to-end efficient production flow is defined and implemented for CLIP.

Contribute to developing and integrating within the production plan a testing regime that provides progressive assurance and captures the information required for handover and maintenance. Integrate quality check sheets, processes and procedures with work instructions from a range of suppliers, specifying how the resulting information will be captured in an auditable manner.

Use existing plans and documentation to identify and resolve both overlaps and gaps between work instructions resulting in a well defined and easily communicated level 5 plan for CLIP production.

Ensure suitable time allowances are made for quality checks within the production plan as per the supplier's inspection and test plan. Allow time in processes for the tests to be witnessed and signed of by the relevant stakeholders and the competent engineers. Ensure that inspection and testing outputs are recorded as assurance evidence to be issued to the Maintainer at handover.

Ensure that the production process minimises scheduled and minimises unscheduled production work, enabling the proactive and efficient utilisation of resource to deliver the programme.

Responsible for liaising with stakeholders at programme level on behalf of the production labour workforce, including but not limited to the customer Engineering and Materials teams to support the production scope and meet business requirements.

Definition and use of suitable Key Performance Indicators for the plan you produce.

Definition and use of IT systems as necessary to interrogate for information on defects, workload and report on completed works, outstanding or deferred.

Run lessons learnt workshops to secure money and time savings through process improvements.

Skills, Knowledge & Experience

Skills

Good leadership skills with a good level of oral & written communication and interpersonal skills.

Electrical, electronic, and mechanical skills relevant to rolling stock.

Able to understand maintenance plans, quality assurance processes and work instructions, to schedule staff to carry out work against them.

Able to deal with suppliers and to tailor approach to differing circumstances.

Ability to be flexible & supportive.

Good record keeping.

Ability to work as a part of a large multi-site production management team.

Ability to influence and engage a large workforce with diverse skills and experience spread over multiple worksites.

Knowledge

Appropriate management qualification or have served an engineering apprenticeship or substantial experience in relevant fields such as rolling stock, production setup or logistical undertakings.

Technical and practical knowledge of relevant rolling stock is highly desirable.

Knowledge of safety legislation, safety processes and quality management procedures.

Experience

Experience of working in the workshop production environment or similar engineering environment with appropriate apprenticeship served being highly desirable.

Experienced in managing or coordinating large teams across multiple sites.

Excellent communication experience, and proven track record in achieving required outcomes in hostile and conflicting situations with tact, diplomacy and sensitivity.

Experience of implementing 6 SIGMA and Lean manufacturing processes and Visualisation tools.

Experienced in the use of other standard software packages including Microsoft Word/Excel/PowerPoint/Project/P6 and relevant industry software.