Darryl Guess
Swindon,United Kingdom
Summary
Experienced professional with a strong background in manufacturing, team leadership, and continuous improvement. Demonstrates expertise in man management, team development, and quality assurance. Proven ability to enhance efficiency through KPI identification and implementation, process sequencing, and cost impact analysis. Adept at managing budgets, negotiating effectively, and ensuring health and safety compliance. Committed to understanding customer expectations and driving team performance through logical approaches and sound direction. Skilled in 5S methodology and maintaining calm under pressure while motivating teams towards excellence.
Overview
31
31
years of professional experience
1
1
Certification
Work history
Production Operations Manager (BIW-BODY ASSEMBLY)
McLaren Automotive
Woking, UK
08.2023 - 01.2025
- Manage staff of 3 Group Leaders, 8 Team Leaders, and 132 Technicians
- Oversee rota planning and monitored staff leave and absences
- Conduct candidate interviews and assessments efficiently
- Manage McLaren's annual employee appraisal programme
- Plan and facilitate team development programmes
- Manage discipline and resolved conflicts
- Monitor cycle time and schedule adherence, implementing contingency plans for negative trends
- Manage balanced workloads aligned with budget and provided appropriate training
- Track consumable spending and implemented cost-saving measures
- Ensure adherence to safe working practices and correct protective clothing usage
- Conduct disciplinary processes in partnership with HR
- Oversee health and safety procedures including SOTs and risk assessments
- Manage on-site evaluations, internal audits and team surveys.
- Generate Key Performance Indicator reporting to drive better performance.
- Oversee PPE utilisation and conducted health surveillance
- Prioritise activities and distributed workload in line with cross-functional team
- Support MMS to maintain workshop environment to McLaren's high standards
- Evaluate continuous improvement structures for process enhancement
- Plan short, medium, and long term headcount against programme requirements
Production Operations Manager (ASSEMBLY FRAME)
McLaren Automotive
Woking, UK
09.2017 - 08.2023
- Team personnel management: Rota planning, Holiday and Absence Tracking
- Recruitment
- Management of McLaren's annual appraisal system
- Team development planning, Training, Coaching and Mentoring
- Discipline and Conflict resolution
- Managing a staff of 4 Group leaders, 6 Team Leaders and 145 Technicians, 4 Quality Inspectors, 4 Reworkers
- Cycle time and schedule adherence, present and have contingency planning in place if negative trends are incurred
- Ensure balanced workloads are managed throughout the shift by ensuring head count allocation is aligned to budget, coupled with appropriate training
- Monitoring & reporting against consumable expenditure, driving down reduction
- Ensure safe working practices are adhered to and that all Team Members are using the correct protective clothing
- Conduct disciplinary investigations or disciplinary meetings with the assistance of HR
- Health and Safety: Including but not limited to the management of SOT's, Risk assessments, TPM's, accident reporting, QCR management
- Occupational health monitoring and PPE
- Workshop activity planning: Weekly production scheduling in conjunction with the production manager, prioritisation of activities and workload distribution in line with the cross functional team members of development
- Supporting MMS to ensure the workshop environment is maintained and in line with the standards expected of McLaren
- Future planning: New business strategy planning in union with the head of department, evaluating continuous improvement structures in terms of process and best practise to better serve development
- Short, medium and long term headcount planning against program requirement
Group Leader (ASSEMBLY FRAME)
McLaren Automotive
Woking, UK
02.2016 - 09.2017
- Team personnel management: Rota planning, Holiday and Absence Tracking
- Recruitment
- Management of McLaren's annual appraisal system
- Team development planning, Training, Coaching and Mentoring
- Discipline and Conflict resolution
- Managing a staff of 55 technicians including x3 Team Leaders
- Health and Safety: Including but not limited to the management of SOT's, Risk assessments, TPM's, accident reporting, QCR management
- Occupational health monitoring and PPE
- Workshop activity planning: Weekly production scheduling in conjunction with the production manager, prioritisation of activities and workload distribution in line with the cross functional team members of development
- Supporting MMS to ensure the workshop environment is maintained and in line with the standards expected of McLaren
- Future planning: New business strategy planning in union with the production operations manager of department, evaluating continuous improvement structures in terms of process and best practise to better serve development
- Short, medium and long term headcount planning against program requirement
Future Model Manufacturing Engineer (ASSY FRAME)
McLaren Automotive
Woking, UK
07.2014 - 02.2016
New Model Process Team (ASSEMBLY FRAME)
Honda of the UK Manufacturing
Swindon, UK
01.2009 - 07.2014
- Process Lead role within the new model process team for regular Japan travel events, TV conferences, team status reports, new model packaging, jig and tooling ordering to delivery
- Catia study of parts for fitment and good process flow ensuring tightening lines and fitment are achievable
- Regularly working away in Japan building the car by using Catia drawings at early stages and hands on approach on further trips on building the car to the process sequence required working with the designers
- Creation of a new model process role, working with designers in Japan to create a product that can be produced in a mass production environment
- Studying design changes to create or update a workable process flow
- Health and safety, Ergonomic, cost reduction, fitment concerns with the new technology
- Setting required manpower based on production volume across two production plants for a smooth new model launch
- Lead role in the development of processes from a new model stage into mass production + 3 months
- Changes to processes to match production volume and sales demand
- Introduction of new technology tooling and process related equipment to improve workability
- Development and maintenance of process related documentation
- Relevant work schedules and projects
- Presenting and reporting on monthly control items and KPI's
- Process condition of line side parts, new tooling and process layout and process aid jigs
- Cost down themes, reducing non value added work elements including QCDMS
- Development of repeatable, cost efficient assembly processes and documentation that will produce the required quality in mass production
- Development, maintenance and support to the production areas for line tact changes, new model introduction's and model transfers
- Improving Quality, Cost and Delivery performance, with a smooth new model introduction through the introduction of new technology tooling and process methods
- Support to the equipment department, with the installation and production trials of new equipment
- Operation standard creation and updates including quality data
- Ensuring PQCT, IPL, Pac-v and MOST study has been implemented
- All of this covers three Honda models over two production plants
Mass Production Process Team (ASSEMBLY FRAME)
Honda of the UK Manufacturing
Swindon, UK
12.2004 - 01.2009
- Setting required manpower based on production volume across two production plants
- Changes to processes to match production volume and sales demand
- Introduction of new technology tooling and process related equipment to improve workability
- Development and maintenance of process related documentation
- Relevant work schedules and projects
- Presenting and reporting on monthly control items and KPI's
- Process condition of line side parts, tooling and process layout
- Cost down themes, reducing non value added work elements
- Development of repeatable, cost efficient assembly processes and documentation that will produce the required quality in mass production
- Development, maintenance and support to the production areas for line tact changes and model transfers
- Improving Quality, Cost and Delivery performance, in mass production through the introduction of new technology tooling and process methods and efficient processes
- Support to the equipment department, with the installation and production trials of new equipment
- Operation standard updates including quality data
PAC-V (ASSEMBLY FRAME)
Honda of the UK Manufacturing
Swindon, UK
08.2000 - 12.2004
- Leading a team of 8x associates to introduce a new model to the factory with minimal impact of any outflows
- Working with the process engineer, understanding the most efficient way to assemble the car, including any additional over checks or Pac-v issues
- Confirming the process and operation standards are clear and written in a clear defined way that any unskilled associate could understand
- Random process audits to confirm all Grade ‘A' items are being fitted and tightened correctly
Assembly New Model Launch Trainer (ASSY FRAME)
Honda of the UK Manufacturing
Swindon, UK
03.1997 - 08.2000
- Working within a small team of associates to introduce all new models to line
- Working with the process engineer, understanding the most efficient way to assemble the car, train and coach associates to complete a process efficiently
- Write the process operation standards in a clear defined way that any unskilled associate could understand
Assembly Floater / Holiday Cover (ASSEMBLY FRAME)
Honda of the UK Manufacturing
Swindon, UK
05.1994 - 03.1997
- Working on a production line collecting daily quality checks from the cars being built online and inputting this data on to the database to complete the x – rs and other quality control tools
- This was also confirming the Grade ‘A' parts were being fitted and tightened to the correct standard required as stated through the (IPL) Important Process List
- Covering processes in this function during associate absences
- Assisting the Team Leader with their daily tasks
- Covering the Team Leader in their absence
Skills
- Manufacturing experience
- Man management
- Team development
- Good communication
- Sound direction
- Logical approach
- KPI identification and implementation
- Quality assurance
- Efficiency improvement
- Understanding of customer expectations
- Process sequencing
- Cost impact analysis
- Manpower head count study
- Production environment knowledge
- Budget management
- Negotiation skills
- 5S methodology
- Health and Safety
- Continuous improvement
- Team performance management
- Quality Assurance
- Calm under pressure
- Team leadership and motivation
Custom
- Microsoft Office, Excel | PowerPoint | Word
- Ergonomics
- FMEA / PFMEA / DFMEA
- Poka Yoke
- Pac-V
- Health and Safety
- Quality Awareness
- Train the Trainer
- High Voltage
- Lean Manufacturing
- 5S
- Continuous Improvement
- Q, C, D, M, S, E (Quality, Cost, Delivery, Morale | Manpower, Safety, Environment)
- Project Planning
- Business Management and Improvements
- Senn Delaney – (Management Leadership Programme)
- MEP Leadership. (Manager Effectiveness Programme)
- What we say, what we do
- People Skills
- Conflict and Assertiveness Skills
- Conflict Resolution
- Appraisals
- Personnel Disciplinary
- Recruitment
- HR Redundancy Consultations
Certification
NCFE CACHE LEVEL 2 CERTIFICATE IN UNDERSTANDING MENTAL HEALTH FIRST AID AND MENTAL HEALTH ADVOCACY IN THE WORKPLACE
Unlts:
A/617/8261 - EXPLORING MENTAL HEALTH - Level 2
K/617/A269 - UNDERSTAND HOW TO SUPPORT INDIVIDUALS WITH MENTAL ILL HEALTH - Level 2
D/617/a.270 - UNDERSTAND A, MENTALLY HEALTHY ENVIRONMENT - Level 2
Personal Information
Nationality: British
References
References available upon request.
Timeline
Production Operations Manager (BIW-BODY ASSEMBLY)
McLaren Automotive
08.2023 - 01.2025
Production Operations Manager (ASSEMBLY FRAME)
McLaren Automotive
09.2017 - 08.2023
Group Leader (ASSEMBLY FRAME)
McLaren Automotive
02.2016 - 09.2017
Future Model Manufacturing Engineer (ASSY FRAME)
McLaren Automotive
07.2014 - 02.2016
New Model Process Team (ASSEMBLY FRAME)
Honda of the UK Manufacturing
01.2009 - 07.2014
Mass Production Process Team (ASSEMBLY FRAME)
Honda of the UK Manufacturing
12.2004 - 01.2009
PAC-V (ASSEMBLY FRAME)
Honda of the UK Manufacturing
08.2000 - 12.2004
Assembly New Model Launch Trainer (ASSY FRAME)
Honda of the UK Manufacturing
03.1997 - 08.2000
Assembly Floater / Holiday Cover (ASSEMBLY FRAME)
Honda of the UK Manufacturing
05.1994 - 03.1997
NCFE CACHE LEVEL 2 CERTIFICATE IN UNDERSTANDING MENTAL HEALTH FIRST AID AND MENTAL HEALTH ADVOCACY IN THE WORKPLACE
Unlts:
A/617/8261 - EXPLORING MENTAL HEALTH - Level 2
K/617/A269 - UNDERSTAND HOW TO SUPPORT INDIVIDUALS WITH MENTAL ILL HEALTH - Level 2
D/617/a.270 - UNDERSTAND A, MENTALLY HEALTHY ENVIRONMENT - Level 2
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