Mark Bibby

Accomplished Operations and Continuous Improvement Leader with over 20 years of experience driving operational excellence across manufacturing, packaging, engineering, and warehouse environments. Proven track record of leading large-scale operations, improving productivity, reducing costs, and enhancing quality through strategic leadership, process optimisation, and continuous improvement initiatives. Experienced in building high-performing teams, delivering sustainable business improvements, and implementing operational strategies that increase efficiency, reliability, and customer satisfaction while maintaining the highest standards of safety, compliance, and quality.

Recognised for translating business objectives into measurable results through strong people's leadership, data-driven decision-making, and a culture of continuous improvement.

Operations Manager (Full-Time Operational Leadership Role) - Belmont Packaging

(2023-01)

Initially appointed on a consultancy basis to establish operational structure and improve performance within a start-up manufacturing site.

• Lead overall operations across Production, Warehouse, and Engineering departments, ensuring efficient daily site performance.
• Implemented SQCDP methodologies across all production lines with measurable KPI tracking, action plans, and continuous improvement initiatives.
• Increased production output by 25% through performance monitoring, visual management systems, and operational improvements.
• Developed and introduced a comprehensive skills matrix that supported succession planning and contributed to increasing workforce multi-skilling from 20% to 80%.
• Improved multi-skilled workforce capability from 20% to 80% by delivering structured cross-training programmes and maintaining individual training records.
• Managed operational, transport, and engineering budgets effectively, consistently maintaining expenditure below target levels.
• Conducted regular audits covering Health & Safety, Quality, 5S, SMED, and waste reduction initiatives to ensure compliance and operational excellence.
• Maintained industry-leading MTTR and MTBF performance through strong collaboration with the engineering maintenance team.
• Supported a high-performing workplace culture that contributed to low customer complaint levels, improved employee engagement, and retention of an 80% multi-skilled workforce.

Operations Manager (Manufacturing Site Leadership Role) - Krystals Packaging, Ellesmere Port - Ellesmere Port

(2021-01 - 2023-12)

• Initially appointed on a consultancy basis to establish operational structure and improve performance within a start-up manufacturing site.
• Introduced leadership frameworks, operational procedures, and workforce planning strategies to stabilise site operations.
• Reduced dependency on agency labour by recruiting and developing a permanent multi-skilled workforce across Operations, Engineering, and Management.
• Prepared the business for successful 24/7 production operations through strategic staffing and operational planning.
• Developed KPI systems and production processes that supported the successful transition to 24/7 operations and contributed to reducing customer lead times from 35 days to 5 days.
• Reduced customer lead times from 35 days to 5 days through process optimisation and production planning improvements.
• Implemented strict Health & Safety procedures, contributing to zero lost-time accidents during tenure.
• Supported business growth and customer satisfaction by ensuring on-time delivery of high-quality products.
• Led continuous improvement initiatives across manufacturing operations, focusing on productivity, efficiency, waste reduction, and operational excellence.
• Delivered training workshops on SMED, 5S, first-level maintenance, and operational best practices to improve workforce capability and performance.
• Worked closely with Engineering and Operations teams to enhance staff performance, project delivery, and operational standards across the site.
• Chaired weekly design and production meetings to minimise downtime and optimise tooling, product design, and machine efficiency.
• Played a key role in implementing SPS (Saica Production Systems) as part of Saica ECO customer satisfaction initiatives.
• Achieved 100% SPS compliance, making the site the first of 10 UK manufacturing plants to reach full compliance standards.
• Designed and implemented process improvement boards across all production lines, improving operator engagement, accountability, and performance visibility.
• Standardised production training programmes and developed SOPs for production, maintenance, and cleaning procedures.
• Increased Overall Equipment Effectiveness (OEE) by 15% through structured continuous improvement initiatives and operational performance management.
• Reduced manufacturing waste by 2%, generating annual cost savings of approximately £300,000.
• Delivered additional annual savings of £70,000 by reducing product trim waste through targeted process optimisation projects.
• Implemented waste reduction initiatives at the Hartlepool site that generated annual savings of approximately £150,000.
• Developed multi-skilled teams that improved safety, quality, productivity, and operational performance while strengthening workforce flexibility.

Business Improvement Manager - Saica Pack, Wigan - Wigan

(2010-01 - 2020-12)

• Led continuous improvement initiatives across manufacturing operations, focusing on productivity, efficiency, waste reduction, and operational excellence.
• Delivered training workshops on SMED, 5S, first-level maintenance, and operational best practices to improve workforce capability and performance.
• Worked closely with Engineering and Operations teams to enhance staff performance, project delivery, and operational standards across the site.
• Chaired weekly design and production meetings to minimise downtime and optimise tooling, product design, and machine efficiency.
• Played a key role in implementing SPS (Saica Production Systems) as part of Saica ECO customer satisfaction initiatives.
• Achieved 100% SPS compliance, making the site the first of 10 UK manufacturing plants to reach full compliance standards.
• Designed and implemented process improvement boards across all production lines, improving operator engagement, accountability, and performance visibility.
• Standardised production training programmes and developed SOPs for production, maintenance, and cleaning procedures.
• Increased Overall Equipment Effectiveness (OEE) by 15% through structured continuous improvement initiatives and operational performance management.
• Reduced manufacturing waste by 2%, generating annual cost savings of approximately £300,000.
• Delivered additional annual savings of £70,000 by reducing product trim waste through targeted process optimisation projects.
• Implemented waste reduction initiatives at the Hartlepool site that generated annual savings of approximately £150,000.
• Developed multi-skilled teams that improved safety, quality, productivity, and operational performance while strengthening workforce flexibility.

Maintenance Manager (Secondment to Engineering Team) - Saica Pack, Wigan - Wigan

(2019-01 - 2020-12)

Appointed to oversee maintenance operations due to extensive operational and machinery knowledge.

• Managed production planning and resource allocation to meet operational demand and maximise productivity.
• Coordinated conversion machine schedules and engineering maintenance requirements to minimise downtime.
• Supported waste reduction initiatives and ensured machines operated at optimum efficiency levels.
• Worked closely with Customer Service and Sales teams to support production planning and customer delivery requirements.
• Assisted in defining operational KPIs and improving planning processes across the business.
• Maintained smooth plant operations while consistently achieving daily, weekly, and annual performance targets.
• Identified and implemented process improvements that consistently support operational KPIs and customer delivery targets.

Conversion Planning Manager - Saica Pack, Wigan - Wigan

(2004-01 - 2010-12)

• Managed production planning and resource allocation to meet operational demand and maximise productivity.
• Coordinated conversion machine schedules and engineering maintenance requirements to minimise downtime.
• Supported waste reduction initiatives and ensured machines operated at optimum efficiency levels.
• Worked closely with Customer Service and Sales teams to support production planning and customer delivery requirements.
• Assisted in defining operational KPIs and improving planning processes across the business.
• Maintained smooth plant operations while consistently achieving daily, weekly, and annual performance targets.
• Identified and implemented process improvements that consistently support operational KPIs and customer delivery targets.
• Consistently exceeded customer delivery targets and operational performance KPIs through effective planning and resource management.
• Successfully resolved complex production planning and operational challenges, minimising disruption to manufacturing schedules.
• Introduced planning and process improvements that enhanced productivity, efficiency, and customer service performance.

Business Improvement Facilitator (Secondment to Business Improvement Team) - Saica Pack, Wigan - Wigan

Machine Operator / Team Leader - Saica Pack / Reed CC / SCA Packaging Ltd

GCSEs Completed - St Edmund Arrowsmith High School, Ashton-in-Makerfield