A cohort approach to solving succession challenges in the stainless-steel industry is underway at the British Stainless-Steel Association as WMG sign up to deliver a second leadership programme for members.

Background and Challenge

Manufacturers consistently recognise the critical importance of enhancing leadership and management skills to bridge existing and anticipated skills gaps and to tackle the major challenges facing the industry. The British Stainless Steel Association members are no different and the association has seen a surge in interest from member firms wanting to develop staff to boost growth and innovation.

Adam Bradley, Director of Corrosion Resistant Materials and Vice Chair of the BSSA said:

“Leadership is not something that is taught. What we find at BSSA is that employees that are good at their job and have worked for a long time in a manufacturing firm are generally made leaders. This type of succession activity does not necessarily translate into success, because a distinct set of skills are required to lead, and you must spend time to learn and embed them. Businesses are finding it difficult to help those employees with that transition and are not investing in training because they don’t know where to go.”

Solution

To help their members thrive and move forward, BSSA and WMG worked together to create a leadership programme crafted specifically for the needs of their members. BSSA realised that the membership base would benefit from a taster of what was available in terms of leadership and development training before investing fully. The BSSA Talent Development Programme consists of two modules helping attendees understand their own leadership qualities and behaviours as well as how to lead a team to success. The programme also provides coaching and an opportunity to work on a cohort project to benefit the businesses as well as the association.

The successful pilot that ran earlier this year resulted in the cohort working together on a directory and support materials to help members better understand the food and drink and interiors sectors where stainless steel has enormous potential and application.

Impacts

As a result of the pilot programme BSSA have committed to offering members the opportunity to join a second Talent Development Programme.

Individuals will benefit from:

• A leadership certificate from the University of Warwick
• Expanding knowledge of products and services within the industry
• The opportunity to network with likeminded individuals
•  Additional skills in areas such as presenting, marketing, social media, project management, as well as a boost in confidence

Benefits to the companies involved include:

• The opportunity to promote their brand
• The opportunity to boost their training and development credentials, which will ultimately boost productivity and attract new skills to the sector

James Sweeney, Production Manager at Birmingham based Anopol Group participated in the pilot programme after being promoted to manage a new team. David Cass, Managing Director at the firm said:

“It has been a pleasure observing James’s growth through the BSSA Talent Development Programme. Our team at Anopol are benefitting from his leadership training and networking interaction development. James has clearly grown in confidence and is demonstrating excellent communication skills, attentive process driven approaches to conflicting situations, and mature self-awareness. He thoroughly enjoyed spending time with the programme lecturers and delegates whilst experiencing new business environments. Our next delegate is ready to go!”

Liz McArdle, Innovation Manager at WMG who delivers the programme alongside colleague Steven Norgrove said:

“We are delighted that Adam and the team have decided to invest in this valuable programme for the second time off the back of the successful pilot. WMG is on a mission to equip the leaders of the future with the skills to navigate changes and opportunities in the manufacturing sector. We thoroughly enjoyed collaborating with the participants and seeing them flourish and grow in confidence. We look forward to meeting the next cohort in October.”

Adam Bradley added:

“Our hope is that schemes like this will help to retain and attract talent to the sector which is vitally important for the association and companies across the board. We are excited to witness the journeys that our next set of leaders will go on through the programme.”

For more information about membership at the BSSA and joining the programme which starts in October visit:

BSSA Talent Development ProgrammeLink opens in a new window

For more information about WMG’s leadership programmes for manufacturing SMEs contact: wmgsme@warwick.ac.uk

“Working with Made Smarter and having the new system in place has been invaluable for us. It has dramatically improved our production line process and has not only made staff happier but has made it easier for us to onboard new colleagues and products thanks to the system’s ease-of-use.”

Claire Robinson, Managing Director, Wrekin Sheetmetal Ltd

Wrekin SheetmetalLink opens in a new window, based in Telford, manufactures and shapes a wide variety of steel parts and components for a range of sectors, including healthcare, automotive, aerospace, and retail.

Challenge

Although the company were thriving in some areas, there were issues with productivity and data visibility on the shopfloor. They were still printing technical drawings on paper and there were often bottlenecks as one department waited on information from another. The company were not optimised to take on new client products due to a lack of time to develop new processes. This was hindering their ability to grow.

Solution

Managing Director Claire Robinson got in touch with the Made Smarter West Midlands programme, who linked Claire with WMG Engineer, Manikanta Ravi. Mani, with the help of Intern Ravikishore Karuppuswamy, undertook a value stream mapping of Wrekin Sheetmetal’s complete manufacturing process from start to finish, to assess improvement opportunities. He recommended they install a suitable dashboarding solution integrated with current Enterprise Resource Planning (ERP) software MIE Track, using a network of tablets on every machine and in every department to monitor data. Together with WMG’s Denis PelychLink opens in a new window, Made Smarter assisted Wrekin Sheetmetal to access a match-funded grant of £20,000 towards the cost of the new system which reduced the risk associated with the investment.

Impacts

• The new system has allowed Wrekin Sheetmetal to devote more time to new product development which will open new growth areas for the business and will help them meet its targets to double turnover by next year
• With the new system in place, Wrekin Sheetmetal are expected to grow capacity by between 10-15% and create seven new jobs
• Wrekin Sheetmetal is now a paperless operation and is using data to drive decision making
• Staff are highly motivated as they now have visibility of their activity, there is reduced time wastage, and they feel bought into the whole manufacturing process. Existing roles will benefit from upskilling going forward

WMG's Manikanta Ravi said:

“Key data such as machine uptime and downtime, technical drawings, and order information is now instantly accessible to every member of the team, with information constantly updated in real time.

The new system has meant the waste identified in our value stream mapping exercise, such as the time taken for the engineering team to pass on drawings to the shop floor team, has been virtually eliminated.”

For the full case study visit:

made-smarter-case-study-wrekin-sheetmetal.pdf (madesmarter.uk)

If you are a manufacturing organisation wanting to work with WMG’s SME team visit:

WMG SME Group Engagement Form (office.com)

Telford based Bridge Cheese has gained two prestigious awards for the way it has harnessed digital technology to grow turnover to £30m in five years. Working with WMG through Made Smarter West Midlands, they have implemented a series of recommendations that have improved efficiency and enabled growth.

Background

Bridge CheeseLink opens in a new window, based in Telford, supplies a variety of cheese and dairy products to the wholesale market, with many of its customers working in the food service industry or food manufacturing. Since its inception in 2018, it has grown rapidly, achieving double-digit growth year-on-year.

Challenge

Bridge Cheese had a mission to double its turnover from £30 million to £60 million in three years. However, to mitigate the pressures of rising costs and to maximise profitability, the two directors Michael Harte and Martin Bowden knew they had to tackle the efficiency of their processes. They were also keen to address issues with stock control and production management.

Michael Harte said:

“We realised that for us to grow further, the analysis of our production processes and costs needed to be a lot better. We had previously relied on spreadsheets and paper records to monitor much of our business’s performance.”

They were aiming to create a smart paperless factory with some automation that would enable them to grow without too much additional labour.

Solution

Telford and Wrekin Council referred the duo to the Made Smarter West Midlands scheme and Made Smarter digital expert Martyn Mangan recommended WMG come in to undertake a thorough audit. This included a “Digital Roadmap” highlighting the steps needed to digitise the business and boost productivity.

WMG's Denis PelychLink opens in a new window worked with Bridge to understand their requirements and what was impeding their growth potential. He suggested a new Enterprise Resource Planning (ERP) system would help improve real time data and visibility to better manage processes. He reviewed various solutions and providers before recommending a specialist food industry package with proven integration to Sage 200, which they were currently using.

The software and services cost was £70k but through Made Smarter, Bridge was able to access a £20k grant. During 2023 using a phased approach, the company implemented the new system which included customised KPI/status dashboards for factory visibility and decision-support.

Impacts

Now up and running, the new system handles everything from tracking orders, stock taking, monitoring machine uptime and downtime, and producing instant quality control reports. Key expected benefits include:

· 20-30% year-on-year growth expected, from £30m to £60m+ revenue in 3 years, including increasing export sales from 2% to 20%+

· 100% reduction in ‘on-time delivery failures’ of orders, plus a saving of the time wasted resolving production issues due to stock issues

· 15-20% improvement in current process efficiency, from process automation across order processing, planning, and production execution

· 10-15% additional efficiency improvement through shop floor digitisation of food safety compliance data capture and management

· 50% reduction in stock days which is around £1.5million of cash freed up to support investment

The outstanding results led to Bridge Cheese being crowned as overall winner of the Made Smarter Adoption Award for the West Midlands region in Birmingham as well as in their own area of the Marches. They represented the West Midlands at the national Made Smarter Awards on 27^th June.

Testimonials

“For SMEs like us, support from a scheme like Made Smarter is so important. As part of this journey, Denis’s role became akin to a “non-executive director” advising us in all matters IT related. We are now taking the next steps towards a digital future for our business, and we would encourage others in our position to do the same.”

Michael Harte, Director, Bridge Cheese Ltd

“Bridge Cheese were a delight to work with and are highly motivated to build on their already excellent reputation for service quality. The new system will enable them to achieve their growth ambition without any risk to delivering on client expectations. There are many additional areas that they can focus on with digital going forward such as further automation which is very exciting.”

Denis Pelych, Digital Manufacturing Advisor, WMG, University of Warwick

To find out more about working with WMG on digitising your business contact WMG's SME TeamLink opens in a new window

For further information on Bridge Cheese visit: Welcome to our World of Cheese - Bridge CheeseLink opens in a new window

To read the full story and watch the video about Bridge Cheese’s journey on Made Smarter visit: Case Study - Bridge Cheese | Made SmarterLink opens in a new window

“Our involvement with the Made Smarter programme gave us the confidence to move forward with one of biggest changes to the company in its 22-year history. This investment will not only allow us to improve our efficiencies but also provide us with the security to continue to grow in the future, aiding us to deliver even better products and services to our customers and ensure we remain a leader in the industry.”

Natalie Benwell, Commercial Manager, Goodflex Rubber Ltd

Warwickshire based Goodflex Rubber Ltd are world renowned manufacturers of high quality, bespoke-design silicone hoses, serving a range of industries including automotive, pharmaceutical, renewable energy, and food.

Challenge

Goodflex had plans to double their turnover over the next three years but were concerned that their Factory Management System was holding them back from achieving this growth. They had been using their current bespoke ERP system since the business was started and it had evolved over time to be used for multiple areas within the business, including material resource planning, accounts, stock management, work order management, invoicing, and delivery notes.

But they needed to move to software which would enable their day-to-day operations to be more efficient, allow them to respond more quickly to their customers and futureproof their processes.

Solution

Commercial manager Natalie Benwell got in touch with the Made Smarter West Midlands programme and was introduced to WMG’s Denis Pelych who quickly set about understanding the company’s specific requirements. It was clear that Goodflex needed an enhanced, futureproof, digital system to drive efficiencies and maintain control of some of their more complex product builds, but they were unsure what specific system to invest in.

Denis conducted a two-stage MRP and ERP* vendor selection process, with Made Smarter support and helped Goodflex select an ERP system that offered the capability they needed today, with a degree of futureproofing. The investment required was approximately £100k but Goodflex were able to access £20k with the help of a Made Smarter grant.

Natalie said:

“Denis understood and identified our needs better than we understood them ourselves and then successfully translated them into an RFP (Request for Proposal) that was such a true reflection of our business. His knowledge in the industry, not only opened our eyes to what was possible, but also took us down a route we never knew existed.”

Impacts

• The new system will help Goodflex increase the speed of response to their customers
• The new system will help Goodflex double their revenue to £10m in three years, with the potential to reach £15-20m in five years, whilst maintaining margins and investment
• The system will lead to a 20-30% efficiency improvement from the automation of business processes
• The company expect to see a 15-20% improvement in material supply and stock efficiencies
• Efficiencies gained through the system will lead to higher levels of profitability
• The new system provides better management information with the ability to set KPIs and have greater operational insight in order to make data driven business decisions
• The new system will also improve Goodflex’s business development strategy enabled by greater insight into costs and opportunities
• The new system has improved workplace motivation and will help to retain and develop highly skilled staff

*ERP vs MRP: What’s The Difference? – Forbes Advisor

Read the full story on the Made Smarter website here.Link opens in a new window

“Working with WMG again has been really beneficial for us. This project will enable us to lower our carbon emissions, something critical for us from both a CSR perspective and in combating rising energy costs to remain competitive.”

Steven West, Head of Operations, Armac Martin Ltd

Background

In 2021, following the introduction of the UK Government’s Net Zero strategy, luxury brass hardware manufacturer, Armac Martin was one of the first companies to join WMG’s Net Zero Innovation (NZIN) Progamme. They collaborated with us to implement sustainable packaging for key product lines in their business. After exploring recyclable, compostable, and returnable options, a cost effective and biodegradable paper-based material was selected which reduced packing time significantly, leading to productivity gains in the business.

Challenge

With renewed drive to reduce emissions by 50% by 2025 and reach Net Zero by 2041, Armac Martin wanted to work with WMG again to see where they could best focus their attentions to achieve these goals. They joined the NZIN programme on a second cohort alongside Brandauer, Sarginsons, Modpods and McGeoch.

Solution

WMG examined how the company could reduce emissions across Scope 1,2 and 3[i] in the business, through a Greenhouse Gas Accounting project. We highlighted a range of opportunities for them to take onboard as part of a five-year roadmap for sustainable change aligned with business visions and priorities through a NZIN roadmap. Representatives from the company also participated in several workshops hosted by WMG.

Impacts

· The company now have a clear vision of how they are going to reach their 2025 and 2041 targets with an action plan to reduce energy costs in the business, including using data to optimise energy usage, as well as voltage optimisation, insulation, and variable speed drives of machinery,

· They plan to install Solar PV Panels to reduce energy related emissions and susceptibility to grid price fluctuations

· They have the opportunity to access grant funding to install the Solar Panels of up to £100,000,

· They now have a robust sustainability strategy which they communicate to both internal and external stakeholders.

“Armac Martin are a company committed to sustainability and it was great to work with them on a second project looking at energy usage in the business. They are a shining example of how businesses can work towards Net Zero targets while adding value to their clients’ customer experience.”

Archit Tamboli, Technology Transfer Engineer, WMG, University of Warwick

For more info on Armac Martin’s sustainability strategy visit:

https://www.armacmartin.co.uk/

“In the last couple of months, we have almost doubled our output compared to 18-24 months ago and we can all see the benefits of the new system compared to our old processes. Our turnaround time has been reduced significantly and there are fewer mistakes to be corrected which is another bonus.”

Ben Simpson, Co-Managing Director, MyWorkwearLink opens in a new window

Challenge

Under the leadership of Managing Directors Ben Simpson and James Worthington, MyWorkwearLink opens in a new window, which was started in 1976, produces thousands of garments every week for companies large and small across the UK. Using state-of-the-art embroidery and print machines, the company adds logos, names and designs onto uniforms, workwear, teamwear, promotional items and other garments. The business also supplies PPE and non-personalised clothing from its 6,500 sq ft premises to its customers predominantly in the Midlands and nationwide.

MyWorkwear was growing rapidly and needed its internal systems to reflect the upsurge in orders.

Ben Simpson, Co-Managing Director, said: “Our systems were starting to struggle because we still had processes in place from a long time ago.”

Solution

Working with partners at Made Smarter West Midlands, colleagues at WMG undertook a digital roadmap which led MyWorkwear to buy a specialist ERP system and software that involves the embroidery machines – which embroider many garments simultaneously – ‘talking’ to a central piece of software. It also enables staff to complete the colourisation and bar code scanning on the garments.

“The comprehensive digital roadmap that we carried out for the business highlighted areas which we felt would improve their productivity. We are delighted to have played a part in improving the digitalisation of MyWorkwear which is already leading to efficiencies, and they are a great example for other West Midlands businesses to follow.”

Onur Eren, Chief Engineer, WMGLink opens in a new window

Impact

Read more here about the project and the results here.Link opens in a new window

For more information about working with WMG's SME Group email wmgsme@warwick.ac.uk