Paul Kelly

Designed and led the implementation of Step-6 'On-the-Job' production transformation within the 6-Step Training Strategy through multi-team workshops. Focused on standardising production training, aligning work environments, and coaching leadership behaviours to drive high performance creating effective, sustainable Process Control. Developed and coached trainers to deliver a multi-skill training course for junior leaders, enabling broader adoption of the Step-6 philosophy beyond initial pilot and rollout.

Supported the internal PowerCo training team with the specialist design and strategic development of a Continuous Improvement Program (CIP), incorporating progressive LEAN methodologies and Production System implementation. The training activity was tailored to the new technology processes specific to battery manufacturing.

Designed and facilitated complex, technically demanding problem-solving workshops in collaboration with responsible ownership teams. Activities included process mapping, data analysis, root cause identification, and the development and implementation of stakeholder-driven countermeasures. These workshops aim at addressing and resolving multiple process delays impacting the readiness phase of manufacturing programs.

Providing technical expertise and specialist support in the design, development and implementation of a benchmark, best-in-class Fundamental Skills Training Centre Campus for oven and cooktop manufacturing. Expanded the original training concept by integrating diverse manufacturing styles and embedding full operator ergonomic experience into the training approach providing the Traunreut plant with a turn-key 'People' development solution.

During the peak of the 2020 COVID-19 pandemic, led the design and development of digital media-based standardised work documentation, specialist training materials, multimedia content, and a dedicated training software delivery system. This initiative supported the rapid upskilling of existing staff within a Ford ME Global Powertrain facility to enable the production of critical medical ventilators.

Interim senior leadership role overseeing the Mould Shop, Aluminising and Coating Plant. Direct operational responsibility for up to 160 staff, with strong focus on training, coaching, mentoring, and development of both the Business Unit and Training Centre teams. Tasked with full performance turnaround, including design and implementation of advanced production systems and practices. Delivered operational excellence while building internal capability to achieve a self-sufficient, high-performing team.

Comprehensive design, development, project management, and installation of a full ‘6-Step’ People Training Strategy—beginning with Step 1: candidate assessment for hiring suitability, and continuing through to Step 6: on-the-job training. The program also includes training delivery for internal Trainers. A key feature of the strategy is the creation of a best-in-class Fundamental Skills Training Area, with a specific focus on Plastic Injection Moulding.

Provided supplier performance improvement expertise and support on behalf of AML at a critical Tier 1 supplier. Led and coordinated the production of all AML parts, ensuring adherence to production plans by resolving quality, technical, and delivery issues through hands-on management and practical problem solving on a daily basis.

Design, supporting development and supporting installation of a 'best-in-class' Fundamental Skill training centre in the field of Cooker Manufacturing Cross functional team project management support and accreditation to the B/S/H/ standard for both Training Area and Trainers

Design, development, installation and project team mentor & management for a ‘process change through new model introduction’ training strategy, targeting Paint Shop & Vehicle Assembly areas which also incorporates production process real-time simulation technical training modules from beginner to advanced levels.

Design, development and installation of a 'best-in-class' Fundamental Skill training centre in the field of Refrigerator manufacturing, incorporating steps 1-4 of the unique Spitfire 6-Step People Development Training Strategy Cross functional team project management and accreditation to a new internal B/S/H/ training centre standard for both Training Area and Trainers.

Provided supplier performance improvement expertise on behalf of AML at a critical Tier 1 supplier. Led and coordinated production performance for DB11 parts, ensuring alignment to plan through hands-on daily management, practical problem solving, and resolution of quality, technical, and delivery issues.

Design, development, and installation of a strategic and comprehensive 6-Step People Development Training Strategy—beginning with candidate assessment for hire suitability and culminating in structured on-the-job training. A key objective was to significantly reduce plant turnover by enhancing workforce readiness and alignment. The program also included the creation of a best-in-class Fundamental Skills Training Area, with a focus on Vehicle Interior Manufacturing.

Delivered immediate, crisis-level support to a Tier 1 supplier, addressing all aspects of product and process performance to resolve critical customer concerns and stabilize direct line operations. Provided targeted coaching to the Plant Manager and leadership team, leveraging Lean tools and techniques to foster a proactive, continuous improvement culture. Facilitated management coaching workshops to embed operational excellence and sustain long-term performance improvements.

Design, development and installation of a best-in-class Fundamental Skill training area focusing on diagnosis & repair standardisation for Maintenance Operators working with a further three ‘state of the art’ New Technology robot fixing techniques including robot crash and robot cell recovery. Cross functional team project management and accreditation to the global standard for both Training Area and Trainers.

Led the design, compilation, and team mentoring for the development of six New Technology Fundamental Skills project portfolio modules. These modules complement standardized training media and form a comprehensive, detailed rollout package to support consistent global deployment.

Design, development and installation of a best-in-class Fundamental Skill training area focusing on diagnosis & repair standardisation for Maintenance Operators working with six ‘state of the art’ New Technology robot fixing techniques for aluminium vehicle body manufacturing. Cross functional team project management and accreditation to the global standard for both Training Area and Trainers.

Design, development and installation of a best-in-class Fundamental Skill training centre in the field of Electric Motor manufacturing. Cross functional team project management and accreditation to the global standard for both Training Area and Trainers.

Design, development and installation of a best-in-class Fundamental Skill training centre in the field of Service Parts Logistics & Operations for VW OTC. Cross functional team project management and accreditation to the global standard for both Training Area and Trainers.