Stephen Kinsey
Blackwood,United Kingdom
Summary
Accomplished, hard working and loyal professional with expertise in strategic operations management and the development of high-performing teams. Demonstrates proficiency in continuous improvement methodologies such as Lean, 5S, and Kaizen, ensuring health and safety compliance while optimising production processes. Skilled in P&L ownership, financial analysis, and project management within manufacturing environments. Adept at labour efficiency, waste reduction, and change management through effective stakeholder engagement. Committed to quality control and audit readiness with a focus on data-driven decision-making and innovative thought leadership. Career goals include driving organisational success through strategic partnerships and visionary leadership.
Overview
21
21
years of professional experience
44
44
years of post-secondary education
Work history
Founder and Lead Consultant
StratOps Consulting
2026.02 - 2026.06
- Developed consultancy service offerings covering operational excellence, continuous improvement, supply chain optimisation, interim leadership, and business transformation.
- Designed operational health check frameworks, diagnostic tools, and improvement methodologies to identify efficiency and profitability opportunities.
- Established business infrastructure, branding, website, marketing strategy, and client engagement processes.
- Conducted market research into operational challenges facing SMEs and manufacturing businesses to shape service offerings and value propositions.
- Built professional networks and strategic partnerships across manufacturing, supply chain, and operational leadership communities.
- Created operational improvement content and thought leadership material focused on Lean manufacturing, continuous improvement, leadership, and operational excellence.
- Leveraged over 20 years of operational leadership experience to develop practical consultancy frameworks and implementation approaches.
- I partner with Operations, Manufacturers and SMEs in FMCG sector to supply short term, long term and interim collaborations across Wales and South West region.
Head of Operations and Supply Chain
Rogers Estates Coffee (UK) Ltd
Caerphilly, Wales
2023.10 - 2025.11
- Headhunted into leading role for $300m group turnover brand and achieved first-year increase of UK and EU revenue of +22%
- Assumed full responsibility of day-to-day planning, procurement, warehouse, supply chain, logistics, engineering and operations, overseeing all aspects of site performance of business that generated £4.5 million turnover in FY24/25 (+£800k vs previous FY23/24).
- Delivered year-on-year profitability improvements through building of ERP planning and forecasting model, raw material cost reduction, budget control and gross margin optimisation.
- Plan attainment volume increased from 4.6T to 5T through effective planning (+8% increase), coinciding with 7% reduction in energy costs and operating hours.
- Spearheaded strategic portfolio simplification and category alignment from market research results.
- Increased B2B and B2C gross margins by 20% through SKU rationalisation and discontinuation of loss-making lines and processes.
- Identified, sourced and managed successful delivery of multiple CAPEX projects and process improvement initiatives. Results/annual savings:- 25% labour reduction through purchase of Check Weigher (£22.5k cost recovered in 9 months - £30k saving YOY)/67% raw material waste reduction and 67% changeover reduction at packaging stage by increasing size of raw material film reels purchased from supplier (combined £50k saving YOY). Reel Lifter purchased to fully automate reel changeover process and reduce changeover time by 67% (15 minutes to 5 minutes). Daily plan attainment increased by 15% (£25k cost recovered in 4 months). Warehouse installation increased on-site storage capacity by 325% whilst downsizing real estate/cutting rental costs by 25% (£15k cost recovered in 5 months - £36k rental saving YOY). All costs fully recovered within 9 months of completion and all providing multiple 6 figure savings over length of CAPEX proposal/accounts.
- Cut cost of Amazon distribution by 90% and increased sales by 80% by moving from D2C to 360-degree E-Commerce solutions provider. Total cost of service resulted in cost reduction of 50% vs D2C distribution model.
- Developed high-performing team culture, converting long-term agency workers to permanent staff, and investing in cross-training and upskilling.
- Oversaw flawless health and safety record (zero accidents in 12 months) and improved site morale through inclusive leadership, training and empowering employees. Employee sickness levels reduced by 90% (FY24/25 vs FY23/24).
- Led transition of packaging operations from manual to automated systems, boosting throughput and operational consistency. Identified and led transition from net weight to average weight across SKU range - yield at packaging stage increased by 3% with forecasted raw material expenditure reduction of£50k per annum whilst generating forecasted revenue of £135k per annum.
- Successfully identified waste and reduced budget forecast/spend by £200k (4.5% - FY24/25 vs FY23/24).
- Spearheaded financial year improvements of £800k in Revenue (22%), £290k in Gross Profit (83%), £300k (374%) in Operating EBITDA, £300k (72%) in Net Income and £330k in Operating EBITDA (FY24/25 vs FY23/24).
- An internationally family-owned and operated company since 1979 which grows, imports, and roasts 100% Arabica and shade-grown coffee beans from around the world under the brand name of San Francisco Bay Coffee
Operations Manager
RF Brookes/2 Sisters Food Group
2021.10 - 2023.10
- Night shift Site Lead, overseeing up to 300 operators and 10 shift managers, at peak weekly volumes of 1.5 million units across 15 production lines in High Risk production area, with accountability of health & safety, supply chain, operations, logistics, quality assurance and meeting customer specifications for site generating annual revenue of over £140 million.
- Delivered operational improvements through waste reduction, labour/material efficiency, and Continuous Improvement initiatives—including CAPEX project that saved £170k annually in labour.
- Developed high performing teams, implementing structured appraisals, training workshops, and performance management to drive KPI attainment and maintain high operational standards.
- Responsible for Process Improvement Programs using Lean tools (5S, Kaizen, TIM WOODS), improving material yields through data-led analysis. Supported both internal and external audits in unionised environment.
- One of largest and most advanced food factories in Europe specifically designed for producing chilled and frozen recipe meals for Major British Multinational Retailers
First Line Manager/Section Leader/Supervisor/Team Leader/Key Operator/Operator
EPC/Billington Foodservice/Bar and Restaurant Foods Ltd
2005.08 - 2021.10
- Managed shop floor day-to-day operations across High Care and Low Risk production areas, along with Frozen/Chilled/Ambient packing areas, spearheading teams of 40–80 operators to meet KPI targets around labour utilisation, plan attainment, production performance and service levels. Developed and promoted over 15 operators internally during time with business.
- Managed raw material stock rotation, responsible for finalising labour and planning schedules to maximise manufacturing efficiency.
- Operated range of machinery, including Vertical Filling lines, Sachet Lines, Bottle Lines, Multivacs and Conveyor Systems.
- Promoted to First Line Manager from Section Leader, Supervisor, Team Leader, Key Op, Operator.
- Supplying UK’s Foodservice, Retail & B2B markets with ambient, chilled and frozen sauces, soups, condiments and ready meals
Education
The Complete AI Bundle for Success - Applied AI and Digital Skills Education
Coursiv
2026.05 -
Business And Admin Level 2 - Business Operations And Administrative Support
NVQ
Lean Six Sigma Black Belt - Business Process Improvement, Operations Management and Quality Management
The Knowledge Academy
2026.01 - 2026.05
Lean Six Sigma Green Belt - Business Process Improvement, Operations Management and Quality Management
The Knowledge Academy
2025.12 - 2026.05
Finance for Non-Finance Manager - Accounting and Finance Training
The Knowledge Academy
2026.01 - 2026.01
Prince2 Practitioner - Project Management
The Knowledge Academy
2025.12 - 2026.06
HACCP Level 2 - Food Science, Public Health and Environmental Health
High Speed Training
2001.04 - 2025.01
Managing Safely - Occupational Safety and Health
IOSH (Institution of Occupational Safety and Health)
/2023 - 2023.01
Food Safety Level 3 - Food Science and Technology
High Speed Training
Business and Management Level 3 - Leadership and Management
Institute of Leadership and Management
2001.04 - 2015.01
AS Levels - Accounting, ICT, Business Admin
Crosskeys College
2003.09 - 2004.07
GCSEs - Maths, English, Science, History, French, PE, ICT
Newbridge Comprehensive School
1998.09 - 2003.07
Skills
- Strategic Operations Management (FMCG & Regulated Environments)
- Development of High Performing Teams
- Production & Process Optimisation through Continuous Improvement initiatives
- Change Management & Stakeholder Engagement
- Supply Chain & Vendor Management
- Data-Driven Decision Making
- Creative problem solving
- Supply chain optimization
- Leadership excellence
- Resilience under pressure
- Budget planning and forecasting
Hobbies and Interests
Passionate about sports, proud follower of Merthyr Town FC. I enjoy the outdoors and the family and I (dog included) are regular campers. I enjoy my fitness. Love my music. Active volunteer and youth coach: Active Team Manager – U12s Rugby, Coach – U5s & U8s Football Teams (2020-2023). Completed Welsh 3 Peaks Challenge, raising over £1,000 for charity.
Timeline
The Complete AI Bundle for Success - Applied AI and Digital Skills Education
Coursiv
2026.05 -
Founder and Lead Consultant
StratOps Consulting
2026.02 - 2026.06
Lean Six Sigma Black Belt - Business Process Improvement, Operations Management and Quality Management
The Knowledge Academy
2026.01 - 2026.05
Finance for Non-Finance Manager - Accounting and Finance Training
The Knowledge Academy
2026.01 - 2026.01
Lean Six Sigma Green Belt - Business Process Improvement, Operations Management and Quality Management
The Knowledge Academy
2025.12 - 2026.05
Prince2 Practitioner - Project Management
The Knowledge Academy
2025.12 - 2026.06
Head of Operations and Supply Chain
Rogers Estates Coffee (UK) Ltd
2023.10 - 2025.11
Operations Manager
RF Brookes/2 Sisters Food Group
2021.10 - 2023.10
First Line Manager/Section Leader/Supervisor/Team Leader/Key Operator/Operator
EPC/Billington Foodservice/Bar and Restaurant Foods Ltd
2005.08 - 2021.10
AS Levels - Accounting, ICT, Business Admin
Crosskeys College
2003.09 - 2004.07
HACCP Level 2 - Food Science, Public Health and Environmental Health
High Speed Training
2001.04 - 2025.01
Business and Management Level 3 - Leadership and Management
Institute of Leadership and Management
2001.04 - 2015.01
GCSEs - Maths, English, Science, History, French, PE, ICT
Newbridge Comprehensive School
1998.09 - 2003.07
Managing Safely - Occupational Safety and Health
IOSH (Institution of Occupational Safety and Health)
/2023 - 2023.01
Business And Admin Level 2 - Business Operations And Administrative Support
NVQ
Food Safety Level 3 - Food Science and Technology
High Speed Training