About me

Aluminium Extrusion Consultant – From Process Expertise to Measurable Results

As an aluminium extrusion consultant with 29 years of international experience, I specialise in extrusion process improvement, die management, technical audits, training and greenfield projects. I help aluminium extrusion companies increase productivity, improve product quality, reduce process losses and achieve better utilisation of their equipment.

My career has taken me from hands-on production and die correction through process engineering and production management to senior operational leadership. This combination of practical shop-floor expertise and management experience allows me to approach manufacturing challenges from both a technical and business perspective.

For more than 14 years, I have held senior leadership positions, including responsibilities as Production Director, Operations Director and Plant Director. I have managed manufacturing organisations of up to 250 employees and worked on industrial projects across Europe, the USA and Asia.

A significant part of my career has been dedicated to the aluminium extrusion industry, where I have worked extensively with extrusion process optimisation, die performance and die management, press productivity, equipment utilisation, scrap reduction, troubleshooting and production organisation.

I have also supported the development, installation, start-up and ramp-up of new extrusion facilities and production lines, including major greenfield projects in South Korea and the United States.

From Shop Floor Problems to Measurable Results

My approach as an aluminium extrusion consultant is practical, technical and data-driven. I work directly with production teams to understand what is actually happening at the press and throughout the production process.

Rather than relying only on theoretical KPIs, I focus on identifying the real causes of lost production time, unstable processes, excessive scrap, quality problems and poor equipment utilisation.

This includes analysing extrusion parameters, billet quality and management, die performance, thermal conditions, die change practices, cooling, handling, stretching, ageing and production organisation.

The objective is straightforward: identify the real production constraints, determine their causes and convert improvement opportunities into measurable results.

Waste Time Insight – WTI

To support this approach, I developed Waste Time Insight (WTI) – a practical methodology for identifying, measuring and understanding production losses directly on the shop floor.

WTI transforms structured production observations into actionable data, helping organisations understand where time and production capacity are being lost, why those losses occur and where improvement activities can generate the greatest operational impact.

The methodology supports measurable improvements in press utilisation, productivity, OEE, recoverable production capacity and waste reduction, while helping production teams establish clear priorities for improvement.

Technical Audits, Training & Operational Support

As an aluminium extrusion consultant, I provide independent technical and manufacturing audits, extrusion process assessments and practical improvement programmes.

My work can focus on an individual extrusion press, a complete production line or the overall manufacturing operation. The objective is not simply to identify problems, but to determine their root causes and establish practical actions that can be implemented by the organisation.

I also provide specialised aluminium extrusion training for production managers, process engineers, die shop teams, supervisors and operators. Training is based on practical industrial experience and focuses on giving teams the technical knowledge and tools required to understand, control and improve their processes independently.

Where required, I support companies with greenfield projects, equipment and supplier selection, line installation, commissioning, start-up and production ramp-up.

Operational & Technical Due Diligence

I also support investors and industrial companies through Operational and Technical Due Diligence, providing independent assessments of manufacturing capabilities, equipment condition, operational performance, technical risks and improvement potential during investment and acquisition projects.

My assessments combine technical analysis, operational experience and practical manufacturing knowledge, helping decision-makers understand both the current condition of an operation and its realistic development potential.

My Approach

I believe sustainable manufacturing improvement comes from combining process knowledge, reliable data, disciplined execution and strong production teams.

My role is not simply to identify problems or produce another report. It is to understand why performance is being lost, identify the technical and organisational causes, define practical solutions and work with the organisation to turn those solutions into measurable and sustainable production results.