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
