Daniel Heywood
Liverpool,Merseyside
Summary
A highly accomplished Engineering Leader with extensive experience delivering maintenance excellence, asset reliability, automation performance and operational continuity across complex, fast-paced manufacturing and distribution environments. Proven track record of developing high performing teams, implementing proactive maintenance strategies, and leading engineering to improve equipment reliability, operational efficiency and business performance. Experienced in contractor management, compliance governance, budget control, capital projects and continuous improvement, with a strong commitment to safety, accountability and delivering sustainable operational results.
Overview
15
15
years of professional experience
1
1
Certification
Work history
Group Engineering Excellence Lead
THG
Warrington
2024.10 - 2026.06
- Leading Engineering Excellence across six UK manufacturing sites, responsible for developing and deploying a group-wide engineering, maintenance and continuous improvement roadmap to improve asset reliability, compliance, facilities standards and operational performance.
- Accountable for supporting site engineering teams with maintenance strategy, engineering escalation, CAPEX justification, compliance requirements, facilities standards and the implementation of consistent engineering best practice across sites with varying levels of maturity.
- Led the rollout of a group CMMS, standardising maintenance execution, work order management, planned preventative maintenance, asset history, spares visibility and engineering performance reporting across the manufacturing network.
- Developed and embedded standardised maintenance strategies, engineering KPIs, RCA processes, SMED activities, group asset care routines and continuous improvement governance to improve reliability, reduce losses and strengthen maintenance maturity.
- Responsible for engineering compliance and facilities improvement across the group, ensuring site teams have clear standards, structured action plans and appropriate support to meet regulatory, safety and operational requirements.
- Led the Group Continuous Improvement team, setting priorities, objectives and improvement strategy across the manufacturing network, using data-led performance reviews to identify opportunities for CI activity, optimisation and capital investment.
- Introduced engineering capability frameworks including skills matrices, apprenticeship development pathways and mentoring structures to improve engineering competence, succession planning and consistency of technical standards.
- Worked closely with, site leadership teams, HSE and external partners to align engineering priorities with business objectives, operational risk and long-term asset strategy.
Automation Performance Manager/ Incident SME
Royal Mail
2020.01 - 2024.10
- Senior technical escalation point for multi-site automation issues, providing expert engineering support for complex faults, performance losses and operational incidents across Parcel Hub operations.
- Owned automation performance metrics across hub sites, using data analysis, reliability trends and operational KPIs to identify improvement opportunities and drive asset availability.
- Developed and implemented structured maintenance strategies, including preventative maintenance plans, autonomous maintenance routines, inspection standards, technical tools and reliability-led asset care processes.
- Established maintenance planning standards and engineering governance to improve PM execution, asset condition monitoring, breakdown response and technical consistency across automation assets.
- Created and supported technical training plans for engineering teams, improving capability across fault finding, maintenance standards, asset care routines and safe working practices.
- Led root cause analysis for breakdowns, technical incidents and recurring faults, developing cost-effective corrective actions to improve automation reliability and reduce repeat failures.
- Owned the Continuous Improvement pillar, applying TPM, Lean and WCM methodologies to reduce waste, defects, minor stops and avoidable downtime.
- Supported the development and deployment of autonomous maintenance standards, enabling greater operator ownership of basic asset care and early abnormality detection.
- Acted as the senior technical lead for Parcel Hubs, monitoring critical performance metrics to optimise automation efficiency, maximise availability and maintain customer quality targets.
- Managed site contingency strategies and FMEA documentation, using structured risk assessment and technical decision-making to protect operational KPIs.
- Supported safety audits, engineering inspections, Safe Systems of Work, risk assessments and PUWER assessments to ensure safe and compliant engineering operations.
- Provided leadership, coaching and technical development for engineering teams across all grades, including training, guidance and individual performance reviews.
- Contributed to budget management, supporting approximately £4 million in staff and non-staff engineering expenditure.
- Managed internal and external stakeholders, working with OEMs, suppliers, project teams, Operations and the wider engineering community to deliver technical improvements and maintain asset configuration accuracy.
Site Maintenance Leader
Royal Mail
Southampton
2016.07 - 2020.01
- Led, coached and developed a team of automation engineers and team seniors, supporting technical capability, performance and engagement.
- Owned the Professional Maintenance / Planned Maintenance pillar within the site WCM framework, driving PM compliance, asset care standards, breakdown reduction, RCA activity and continuous improvement of maintenance performance.
- Owned the site maintenance plan for automation equipment, ensuring asset performance and availability targets were achieved.
- Coordinated preventative, predictive and corrective maintenance activities to maximise equipment reliability and operational uptime.
- Provided hands-on technical support for breakdowns, fault finding, modifications and ad-hoc engineering requirements.
- Acted as the technical interface between Engineering and Operations, ensuring maintenance priorities, risks and updates were clearly communicated.
- Supported the implementation of approved equipment modifications while maintaining asset configuration accuracy.
- Conducted engineering audits and supported reporting, data collection and root cause analysis for maintenance events, performance losses, breakdowns and recurring faults.
- Managed engineering risk assessments and ensured Safe Systems of Work were accurate, available and effectively communicated.
- Monitored maintenance costs and supported control of engineering tools, spares and maintenance activity through SAP-based systems.
- Ensured engineering resources were effectively planned and deployed to meet operational and maintenance demands.
Automation Maintenance Engineer
Royal Mail
2011.07 - 2016.07
- Conducted corrective and preventative maintenance, leveraging machine data analysis to ensure the efficiency, high performance and reliability of automation assets
- Led projects involving local equipment modifications and continuous improvements to achieve successful outcomes
- Acted as a Health and Safety representative, conducting regular local audits
- Developed and implemented programs to systematically eliminate, prevent or control risks, prioritising a safe and compliant working environment
- Secondment to site maintenance leader, overseeing maintenance stock, resourcing and planning ensuring uninterrupted operations.
Education
BTEC & NVQ Level 3 Diploma - Advanced Manufacturing Engineering
Skills
- TPM, WCM & Lean Manufacturing
- BRCGS and Food Safety
- Engineering Leadership
- CMMS & MES Implementation
- KPI & Performance Management
- Capital & Operational Planning
- Root Cause Analysis
- 5S and CI Systems
- Safety & Statutory Compliance
- People Development & Coaching
- Multi-site Transformation
- Data-Driven Decision Making
References
Available upon request.
Affiliations
- EngTech TMIET
Certification
- IOSH Managing Safely
- ILM Level 3 Award in Effective Coaching
- IASSC Lean Six Sigma Green Belt
- Level 3 Food Safety
Timeline
Group Engineering Excellence Lead
THG
2024.10 - 2026.06
Automation Performance Manager/ Incident SME
Royal Mail
2020.01 - 2024.10
Site Maintenance Leader
Royal Mail
2016.07 - 2020.01
Automation Maintenance Engineer
Royal Mail
2011.07 - 2016.07