Beyond the Assembly Line: Inspiring stories from UK factory floors
Arguably the manufacturing sector is leading the charge when it comes to successes and advancements operational excellence.
Today, there are virtually no technological limits to what organisations can accomplish, they are probably only limited to budgets and our imaginations, but thanks to advancements like real-time data collection, cloud computing, and near-instantaneous feedback mechanisms, they all drive manufacturing efficiency.
The Industry 4.0 paradigm has become a cornerstone of the industrial sector, yet, its adoption varies widely across manufacturing.
Consider an injection moulding company with 10 production lines. Without a Manufacturing Execution System (MES) like Intouch Monitoring, it may struggle to compete with a company running more lines but leveraging monitoring software to achieve superior production efficiency.
This highlights the pivotal role enabling technologies play in modern manufacturing, particularly for fast-moving consumer goods (FMCG) companies.
While these technologies are accessible to all, many organisations have yet to fully embrace digital transformation. Perceived obstacles such as outdated equipment, budget limitations or limited resources are increasingly resolvable due to the compatibility of current solutions, the SaaS model and competitive pricing.
In this article, we spotlight manufacturing organisations of different sizes and technological capabilities that have successfully enhanced Overall Equipment Effectiveness (OEE) and profitability. Drawing from success stories shared by Intouch Monitoring clients, we aim to inspire readers to rethink their baseline operations and set achievable goals.
These examples illustrate how starting small, making informed decisions, and scaling over time can lead to significant returns and sustainable growth.
We will now review 4 very different types of projects and showcase how these companies utilised the help of an MES to boost their production efficiency on the factory floor.
Russell Roof Tiles: Driving Efficiency with Intouch
Leading UK roof tile manufacturer Russell Roof Tiles achieved remarkable operational efficiency improvements using Intouch Monitoring’s MES system. With a commitment to innovation and sustainability, Russell Roof Tiles sought real-time data insights to address excess capacity, streamline procurement, and optimise machine utilisation.
Intouch enabled them to improve Overall Equipment Efficiency (OEE) from ~70% to over 90% for 9 out of 12 machines. They also delayed a costly repair by 5 months through precise workload planning based on real-time data.
The system’s user-friendly interface, live shop floor visuals, and customisable features, such as retrospective downtime tracking, proved invaluable. Business Support Manager Daniel Hancox praised the monthly OEE reports and responsive customer support.
Russell Roof Tiles’ partnership with Intouch exemplifies how leveraging digital tools drives data-driven decisions, enhances resource utilisation, and achieves lasting improvements in manufacturing efficiency.
Unette Achieves Over £50,000 in Productivity Gains with Intouch Monitoring
Specialist liquid filling experts Unette transformed their operations with the Intouch Monitoring system, driving productivity gains exceeding £50,000 annually. With 10 filling lines producing up to 25,000 sachets per machine per day, the company sought to overcome bottlenecks, track downtime, and enhance Overall Equipment Effectiveness (OEE).
Before Intouch, Unette relied on manual data logging, delaying insights into production issues. After trialling the cost-effective, cloud-based Intouch system, Marcelo Bras, Manufacturing Support Manager, reported seamless implementation and intuitive usability.
The real-time monitoring allowed operators to address downtime within 10 minutes, saving 6–7 hours weekly across all lines.
Since adopting Intouch, Unette improved OEE from under 70% to 80%, with plans to surpass 90%. The system’s actionable insights and seamless integration with scheduling boosted operational efficiency, supply chain performance, and customer satisfaction.
Marcelo highlights Intouch as an invaluable tool for proactive management, enabling smarter, data-driven decisions.
DCT Saves 60-Man Hours Weekly and Boosts Efficiency with Intouch Monitoring
Diverse Corporate Technologies (DCT), a leading USA-based manufacturer, enhanced productivity by integrating the Intouch Monitoring system, saving 60-man hours weekly and streamlining operations.
Initially relying on manual processes for data collection and job scheduling, DCT faced inefficiencies that hindered visibility into real-time machine performance and quality control.
Intouch’s intuitive drag-and-drop scheduling and automated data reporting replaced manual methods, providing immediate job insights, reducing downtime,
and improving machine utilization. Seamless integration with DCT’s NetSuite ERP system enabled automated workflows from scheduling to invoicing, enhancing transparency and profitability tracking.
Project Manager John Wright highlighted how automation freed staff from manual data entry, while Manufacturing Manager Brent Cordes praised Intouch’s real-time visibility and predictive capabilities for reducing tool change times.
Since implementation, DCT has optimized scheduling, improved efficiency, and empowered operators to focus on quality, showcasing a measurable return on investment and positioning them for sustained growth.
Meridian Medical Boosts Efficiency and Profitability with Intouch Monitoring
Meridian Medical, a leading UK-based medical device manufacturer, implemented the Intouch system in 2021 to enhance production visibility and efficiency. Facing challenges in real-time data access and scheduling due to complex production demands and full capacity, they trialled Intouch’s system, which transformed their operations.
The system, deployed on 12 injection moulding machines, provided Managing Director James Fenton and his team with real-time insights into machine utilisation and job progress. A shop floor screen displaying key performance indicators motivated staff to optimize production rates and reduce tool change times. Enhanced visibility allowed smarter planning, quick adjustments, and better customer communication.
With downtime alerts now prominently visible, the team quickly addresses issues, maximizing machine usage despite space and staff constraints. James Fenton praised Intouch’s customer support for its responsiveness and clarity. The result: streamlined processes, increased efficiency, and improved profitability, making Intouch a game-changer for Meridian Medical.
Stories from the UK factory floor: the facts behind improved operational efficiency
These examples are just a small subset of the collaborative projects that have been undertaken by Intouch Monitoring.
They provide real-world examples of how proactively monitoring a production process, regardless of complexity or incumbent technological capabilities, leads to greater output efficiencies. Adopting a common platform helps to align corporate direction and cross-functional teams to work together in achieving a single set of goals: improving operational excellence.
Every project described above started on a smaller scale to prove that the platform was effective and adopted by a diverse set of stakeholders, growing to a factory wide roll-out within a matter of months.
Read more success stories
Please get in contact with us to find out more about how we help manufacturing organisations of all sizes achieve a common goal.
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How it works
Getting started with Intouch is as easy as 1, 2, 3
1. Book a demo
Let us show you what we can do. Jump on a demo call and our friendly team will take you through the Intouch system and answer any questions you might have.
2. Enjoy a free trial
Don’t just take our word for it! We’ll lend you our technology for a 60-day free trial so you can see exactly how it can benefit the everyday operation of your business.
3. Receive ongoing support
It doesn’t end there. If you decide Intouch is the right production monitoring system for you, we’ll work with you to help you take control and make significant improvements in OEE.