Malcolm Ford
Summary
Well seasoned Dynamic Senior Operations Leader with 25+ years of UK and international experience as Manufacturing Director, COO, and General Manager in manufacturing, packaging, and consumer goods. Recognized for leveraging extensive expertise to drive transformational initiatives, project-based outcomes, and sustainable growth across the UK, Europe, Asia and the US. Passionate about optimizing processes through LEAN methodologies whilst ensuring flexibility to adapt to evolving market demands.
Overview
38
38
years of professional experience
Work History
Chief Operating Officer
PaperFoam Packaging
, USA & CZ
01.2019 - 01.2025
- Global Facility Launch: Successfully designed, built, and launched multiple state-of-the-art manufacturing facilities in the US and Europe. This strategic expansion fueled growth in response to increasing global market demand, resulting in a 25% increase in production capacity within the first year.
- Implementation of LEAN and cGMP Processes: Spearheaded the application of LEAN methodologies and cGMP compliance across operations. Achieved a 30% reduction in waste and enhanced process efficiency, significantly exceeding expectations of multinational clients and setting new industry benchmarks.
- Cross-Functional Strategy Alignment: Collaborated with senior executives and board members to align corporate strategies with operational execution. This approach not only enhanced coordination among different departments but also improved overall strategic agility, resulting in a consistent annual growth of over 7%.
EU Manufacturing Director
Rompa
Czech Republic
01.2010 - 01.2019
- Sales Transformation: Led comprehensive transformation of European operations, successfully increasing sales from €12 million to €28 million over five years. This involved analyzing market trends and adjusting operational strategies to capitalize effectively on emerging opportunities.
- Factory Design & Capacity Expansion: Pioneered design and construction of two new factories in Germany and Slovakia. These facilities were crucial in expanding production capacity and improving operational efficiency, aligning with demand dynamics of European market.
- EU-Wide LEAN Process Implementation: Introduced and standardized LEAN processes across all operations, resulting in exceeding customer financial and performance KPIs. Achieved 15% improvement in on-time delivery and 20% increase in operational efficiency, reinforcing company's competitive advantage in market.
Moulding & Accessories Manager
Black & Decker
Czech Republic
01.2003 - 01.2010
- Value Creation: Directed operations for two major business units, responsible for generating €45 million in added value while managing team of 220. Established plastics business unit that consistently delivered over 7% annual growth, enhancing overall profitability of organization.
- Talent Development: Built strong EU plastics team by implementing comprehensive training and mentoring programs. This commitment to talent development not only heightened team capability but also led to increased retention and engagement rates among staff.
- Performance Optimization: Achieved 100% of KPI targets across €30 million accessories division by implementing Lean business mechanisms. These strategies led to enhanced performance and operational excellence, culminating in significant recognition from both internal and external stakeholders.
Manufacturing Manager
Karner Batts
London
01.2001 - 01.2003
- Managed production processes and enhanced operational workflows, setting the stage for future leadership roles.
Senior Shift Manager
Channel Plastics
London
01.1999 - 01.2000
- Oversaw daily operations and team management, driving process improvements within production cycles.
Operations Manager
Shep Plastics
, East Sussex
01.1997 - 01.1999
- Introduced strategic initiatives that improved product quality and manufacturing efficiency.
Production Manager
Precise Tooling
, West Sussex
01.1992 - 01.1997
- Responsible for overseeing production teams and ensuring compliance with quality standards.
Production Supervisor
THD Manufacturing
, East Sussex
01.1990 - 01.1992
- Managed project timelines and team schedules, contributing to successful project completions.
Senior Technician
Massmould
, Bedfordshire
01.1987 - 01.1990
- Assisted in implementing technical solutions that enhanced production capabilities and efficiency.
Education
Strategic Leadership Training -
PPITB
PITB Injection Moulding Technician -
PPITB
Lean, WCM, 6sigma Green Belt, Kaizen Certifications -
Black & Decker
Business Management Degree - Finance
West Sussex College
07.1996
Skills
- Strategic leadership and governance
- Project management
- Lean methods processes
- Change Management expertise
- P&L ownership
- Cross-cultural leadership
- Coaching and talent development
- Supply chain innovation
- Manufacturing facility design and start-up
- ISO / cGMP process development and integration
- Financial strategy and budget build
- Diverse Team Leadership across many cultures
- Excellent communication skills
Languages
English (Native)
Native
Czech (Conversational)
Elementary
Personal Information
Personal Interests
Club-level motor racing, Constant self-education, Grass roots national tennis, Family Activities
Timeline
Chief Operating Officer
PaperFoam Packaging
01.2019 - 01.2025
EU Manufacturing Director
Rompa
01.2010 - 01.2019
Moulding & Accessories Manager
Black & Decker
01.2003 - 01.2010
Manufacturing Manager
Karner Batts
01.2001 - 01.2003
Senior Shift Manager
Channel Plastics
01.1999 - 01.2000
Operations Manager
Shep Plastics
01.1997 - 01.1999
Production Manager
Precise Tooling
01.1992 - 01.1997
Production Supervisor
THD Manufacturing
01.1990 - 01.1992
Senior Technician
Massmould
01.1987 - 01.1990
Strategic Leadership Training -
PPITB
PITB Injection Moulding Technician -
PPITB
Lean, WCM, 6sigma Green Belt, Kaizen Certifications -
Black & Decker
Business Management Degree - Finance
West Sussex College