Robert Coughlan
Blackwater,Surrey
Summary
Experienced professional with expertise in manufacturing leadership within composites, specialising in motorsport, aerospace, and high-performance automotive sectors. Proven ability to manage cross-functional stakeholders, oversee facility and process setups, and drive production planning while ensuring supplier liaison and resource optimisation. Skilled in technical drawing interpretation, advanced autoclave operation, and quality assurance with a focus on continuous improvement. Adept at performance management, team development, and fostering a culture of health and safety compliance. Committed to delivering operational excellence under pressure while maintaining a strong emphasis on mental health awareness within the workplace.
Overview
29
29
years of professional experience
Work history
Team Leader - Composite Laminating (Night Shift)
McLaren Racing
Woking
2004.01 - 2026.01
- Extensive experience manufacturing F1 chassis, suspension, aerodynamic and structural components using prepreg materials, laser projection systems and engineering drawings.
- Led composite manufacturing teams within a fast-paced Formula 1 environment, supporting production delivery, quality and safety objectives.
- Managed job allocation, workforce utilisation, stock control, and material availability to optimise production priorities.
- Worked closely with engineering, trim shop, logistics and project teams to achieve critical delivery schedules.
- Produced delivery estimates, material forecasts and manufacturing timelines.
- Analysed drawings to identify areas for time, materials, quality, performance and cost efficiencies.
- Developed and documented manufacturing processes for reusable Mossite bag manufacture, repair and maintenance, becoming the recognised subject matter expert and technical lead for design, process improvement and in-house capability development.
- Supported team development and training while ensuring quality assurance and driving continuous improvement initiatives.
Team Leader - Composite laminating
McLaren Cars
Surrey
2000.01 - 2004.01
- Directed a team of 15-20 composite technicians for Mercedes-Benz SLR production activities in South Africa.
- Facilitated supplier development, quality improvement, and training for production ramp-up, enhancing operational readiness and product quality.
- Specialised in resin infusion, preform manufacture, autoclave processing, and composite production methods, ensuring adherence to industry standards.
- Produced prototype and production composite components for McLaren F1, Prost F1, and Mercedes-Benz SLR programmes, contributing to high-performance automotive development.
Composite Laminator
Rumbolds
Surrey
1997.01 - 2000.01
- Manufactured aerospace interior composite structures using phenolic prepreg, Nomex and carbon fibre materials.
- Operated autoclaves, ovens, presses and vacuum bagging systems.
Education
GCSEs - English, Art, Science, Geography, RE and Maths
St Mary's and St Joseph's
Sidcup, KentSkills
- Composite manufacturing leadership
- Advanced autoclave operation
- Technical drawing interpretation
- Quality assurance
- Production planning
- Resource planning
- Facility and process setup
- Stakeholder management
- Problem solving under pressure
- Health and safety compliance
- Team development
- Motorsport, aerospace, and high-performance automotive expertise
- Overhead crane and forklift operation
- Mental health first aid
Affiliations
- Formula One, Golf, Football, Travel, Gym/Fitness
References
References available upon request.
Timeline
Team Leader - Composite Laminating (Night Shift)
McLaren Racing
2004.01 - 2026.01
Team Leader - Composite laminating
McLaren Cars
2000.01 - 2004.01
Composite Laminator
Rumbolds
1997.01 - 2000.01
GCSEs - English, Art, Science, Geography, RE and Maths
St Mary's and St Joseph's