Paul Ainsley
Holme upon Spalding Moor,East Riding of Yorkshire
Summary
Decisive Plant Manager with 30+ years of extensive experience with a strong focus on operational excellence in high-volume, multi-site manufacturing operations across the UK and Europe.
A personable and committed individual with a solid foundation in leadership and known for enhancing production workflows and boosting operational efficiency. Combines deep knowledge of production processes with strong communication skills to optimise plant performance and foster collaborative work environment. Aims to drive continuous improvement and achieve high standards of safety and productivity.
Overview
41
41
years of professional experience
3986
3986
years of post-secondary education
1
1
Certification
Work history
Plant Manager (Gilberdyke)
Mativ – DELSTAR INTERNATIONAL LTD. SPECIALITY MATERIALS MANUFACTURING
E. Yorkshire
02.2023 - 06.2025
- Led site addition of £7M Medical Films line and Clean Room, exceeding profitability targets ahead of schedule.
- Achieved five years without Lost Time or Recordable Accidents, enhancing workplace safety.
- Increased production headcount by 30% to accommodate business growth demands.
- Optimised plant operational structures and logistics, maintaining quality claims below 1% of £25M sales.
- Developed timelines for pipeline projects, effectively managing stakeholder expectations.
- Tracked and analysed performance metrics, identifying areas for operational improvement.
- Coordinated maintenance processes to ensure equipment reliability and maximise uptime.
- Streamlined manufacturing processes to enhance efficiency and revenue generation.
Plant Manager
MATIV – (DELSTAR INTERNATIONAL LTD)
Gilberdyke, East Yorkshire
02.2023 - 06.2025
- Measured on Safety, Quality and Costs targets
- Led site through addition of £7M Medical Films line and Clean Room, driving incremental bottom-line profitability ahead of schedule.
- Reduced downtime with proactive maintenance planning and execution.
- Achieved 5 years without Lost Time or Recordable Accidents.
- Quality claims less than 1% of £25M sales.
- Increased production headcount by 30% to support business growth.
- Specialty Materials Manufacturing
Director UK Operations (AMS & Scapa Industrial)
SWM INTERNATIONAL (Delstar International Ltd)
02.2022 - 02.2023
- Led high-volume tapes and foam product manufacturing, managing 140 staff and generating $90M in annual revenues.
- Implemented Lean Daily Management to minimise waste and enhance revenue.
- Conducted strategic planning sessions to align with corporate objectives.
- Drove process improvements to optimise workflow efficiency and meet product demand.
- Supervised staff development, providing training and support to enhance skill sets.
- Fostered a positive work environment to boost employee morale and retention.
- Streamlined operations through targeted process improvements, increasing overall productivity.
- Recruited high-performing teams focused on talent development and retention strategies.
Director UK Operations
SWM INTERNATIONAL – (DELSTAR INTERNATIONAL LTD)
02.2022 - 02.2023
- Managed high-volume tapes/foam products manufacturing for diverse applications, leading 140 staff and $90M annual revenues.
- Implemented Lean Daily Management process.
- Advanced Materials & Structures Division
Director AMS European Operations
SWM INTERNATIONAL – ADVANCED MATERIALS & STRUCTURES DIVISION
04.2017 - 01.2022
- Oversaw three manufacturing facilities in UK, Belgium, and Poland circa 180 employees, $70M revenues, $11M EBITDA.
- Transitioned UK plant to seven-day work platform, improving lead-time by 30%.
- Drove 48% revenue growth and 50% profitability growth.
Director AMS European Operations
SWM INTERNATIONAL – ADVANCED MATERIALS & STRUCTURES DIVISION
04.2017 - 01.2022
- Oversaw three manufacturing facilities in UK, Belgium, and Poland circa 180 employees, $70M revenues, $11M EBITDA).
- Transitioned UK plant to seven-day work platform, improving lead-time by 30%.
- Drove 48% revenue growth and 50% profitability growth.
Plant Manager
SWM Gilberdyke UK
01.2015 - 03.2017
- Orchestrated business restructuring and TUPE process for 100 staff.
- Delivered 30% growth in revenue and 8% in profit.
- Secured $4M capital investment for new Surface Protection film line and cleanroom facility.
Plant Manager
SWM Gilberdyke UK
01.2015 - 03.2017
- Orchestrated business restructuring and TUPE process for 100 staff.
- Delivered 30% growth in revenue and 8% in profit.
- Secured $4M capital investment for new Surface Protection film line and cleanroom facility.
Operations Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
Kingston upon Hull
10.2009 - 06.2014
- Coordinated two factories producing premium Wound Care brands ($374M turnover).
- Slashed market backorders by 91% and complaints by 51% in 15 months.
- Supported 45% sales growth and delivered 37% improvement in Right-First-Time metrics.
Operations Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
Kingston upon Hull
10.2009 - 06.2014
- Coordinated two factories producing premium Wound Care brands ($374M turnover).
- Slashed market backorders by 91% and complaints by 51% in 15 months.
- Supported 45% sales growth and delivered 37% improvement in Right-First-Time metrics.
Operations Manager, Extruded Films Division
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
03.2007 - 10.2009
- Delivered operational excellence in Customer Care, Manufacturing, Planning, Engineering, Quality, HSE, and Facilities.
- Achieved 90% customer service breakthrough in year one.
- Reduced product defect complaints by 46%.
Operations Manager, Extruded Films Division
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
03.2007 - 10.2009
- Delivered operational excellence in Customer Care, Manufacturing, Planning, Engineering, Quality, HSE, and Facilities.
- Achieved 90% customer service breakthrough in year one.
- Reduced product defect complaints by 46%.
In-Line Adhesives Programme Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2005 - 03.2007
- Designed and installed innovative process for coating film with hot melt adhesive.
In-Line Adhesives Programme Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2005 - 03.2007
- - Designed and installed innovative process for coating film with hot melt adhesive.
Interim Operations Manager
Carrington Wire Ltd. (Acertce Engineering Group)
Halifax
08.2004 - 10.2005
Interim Operations Manager
Carrington Wire Ltd. (Acertce Engineering Group), Halifax
Halifax
08.2004 - 10.2005
Restaurant Proprietor
New World Bistro
Hexham
08.2001 - 02.2004
Restaurant Proprietor
New World Bistro, Hexham
Hexham
08.2001 - 02.2004
Apprentice
Black & Decker Ltd.
Co. Durham
08.1984 - 08.2001
- Apprentice to European QA Manager and introduction of Lean Kaizen
Apprentice to European QA Manager
Black & Decker Ltd., Co. Durham
Co. Durham
08.1984 - 08.2001
- Introduction of Lean Kaizen
Education
Diploma in Business Administration -
Durham University Business School
Durham 1995 - 01.1995
Bachelor of Engineering (Hons) - Electrical/Electronic Engineering
Northumbria University
Skills
- Multi-Site Management,
- Stakeholder engagement
- High-Volume Manufacturing,
- Service Optimisation
- Initiative taking
- Decision Making,
- Change management
- Data analysis
- Production Expansion,
- New Product Implementation,
- Production forecasting
- Cost control strategies
- Budget oversight
- ISO standards proficiency
- Quality Assurance,
- Quality Control Analysis
- Workplace hazard assessment
- Health and Safety Compliance
- Quality Control Analysis
- Quality Assurance,
- Regulatory compliance knowledge
- Process improvement initiatives
- Lean Tools and Techniques,
- Waste reduction techniques
- Team Leadership,
- Collaboration,
- Workforce motivation
- Communication
- Union Negotiations
- Conflict Resolution
- Microsoft Office Suite
Certification
- Portable Appliance Testing (PAT) - 2025-11-03
- S&OP and Integrated Business Planning, Oliver Wight (2009)
- Six-Sigma DMAIC, GE Plastics (1998)
- Kaizen Promotion Office, TBM Consultants (1997)
- Kaizen Shopfloor Breakthrough, TBM Consultants (1997)
- Taguchi Methods of Quality Engineering, ASI Quality Systems (1993)
- Statistical Process Control, Wales Quality Centre (1993)
- Quality Deployment Practitioner Course, ASI Quality Systems (1991)
Accomplishments
- Delivered a $4M Surface Protection Film facility and a $7M Medical Film Facility expansion OTIF, adding strategic capability to the Gilberdyke site while maintaining existing production.
- Maintained an exceptional safety record with 5+ years without Lost Time or Recordable Accidents.
- Led operational integration and TUPE transition following $500M acquisition of Scapa Group, aligning processes and culture across newly combined businesses.
- Drove 48% revenue growth and 50% profit increase by optimising production assets and operational performance across the UK, Belgium, and Poland.
- Transitioned UK site to a 7-day working platform, with Union engagement, delivering 30% growth in revenues.
- Reduced market backorders by 91% and complaints by 51% in 15 months through targeted customer service improvements.
- Consistently implemented Lean tools and Daily Management systems to drive performance, accountability, and cost efficiency.
References
References available upon request.
Timeline
Plant Manager (Gilberdyke)
Mativ – DELSTAR INTERNATIONAL LTD. SPECIALITY MATERIALS MANUFACTURING
02.2023 - 06.2025
Plant Manager
MATIV – (DELSTAR INTERNATIONAL LTD)
02.2023 - 06.2025
Director UK Operations (AMS & Scapa Industrial)
SWM INTERNATIONAL (Delstar International Ltd)
02.2022 - 02.2023
Director UK Operations
SWM INTERNATIONAL – (DELSTAR INTERNATIONAL LTD)
02.2022 - 02.2023
Director AMS European Operations
SWM INTERNATIONAL – ADVANCED MATERIALS & STRUCTURES DIVISION
04.2017 - 01.2022
Director AMS European Operations
SWM INTERNATIONAL – ADVANCED MATERIALS & STRUCTURES DIVISION
04.2017 - 01.2022
Plant Manager
SWM Gilberdyke UK
01.2015 - 03.2017
Plant Manager
SWM Gilberdyke UK
01.2015 - 03.2017
Operations Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2009 - 06.2014
Operations Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2009 - 06.2014
Operations Manager, Extruded Films Division
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
03.2007 - 10.2009
Operations Manager, Extruded Films Division
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
03.2007 - 10.2009
In-Line Adhesives Programme Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2005 - 03.2007
In-Line Adhesives Programme Manager
SMITH & NEPHEW ADVANCED WOUND MANAGEMENT
10.2005 - 03.2007
Interim Operations Manager
Carrington Wire Ltd. (Acertce Engineering Group)
08.2004 - 10.2005
Interim Operations Manager
Carrington Wire Ltd. (Acertce Engineering Group), Halifax
08.2004 - 10.2005
Restaurant Proprietor
New World Bistro
08.2001 - 02.2004
Restaurant Proprietor
New World Bistro, Hexham
08.2001 - 02.2004
Apprentice
Black & Decker Ltd.
08.1984 - 08.2001
Apprentice to European QA Manager
Black & Decker Ltd., Co. Durham
08.1984 - 08.2001
Diploma in Business Administration -
Durham University Business School
1995 - 01.1995
Bachelor of Engineering (Hons) - Electrical/Electronic Engineering
Northumbria University