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Fascia Graphics, Taking a lead

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Manufacturing in Action, Source : The Manufacturer
Zone : Leadership and Lean
Published : April 2007

Fascia Graphics works hard to maintain its prominent market position. Paul Bennett and Mark Anderson gave Robert Pols an insight into the company’s thinking and practices

There’s no false modesty at Fascia Graphics, for the company has a firm belief in its own abilities. “From the very beginning, 13 years ago, our aspiration was to be the market leader in the printing of overlays and keypads,” explained UK sales manager Mark Anderson. “We know we operate in a highly professional manner and give a high level of customer service.”

Established in 1994, the Chippenham-based company uses the latest technologies and techniques for the manufacture of membrane keypads, graphic overlays, labels and associated products. The business grew rapidly, and by 2005 it was clear that new premises were needed to support expansion plans. A 12,000 square foot factory was bought, together with over half an acre of adjacent land, and a new £100,000 printing line was invested in.

“This new facility has enabled us to improve the flow of work and increase efficiency,” Anderson commented. “It has led to better quality control and allowed us to expand. When we moved in 18 months ago, we rattled around in here, but now we’re making effective use of almost all the space. While the market in general is in regression, Fascia is bucking the trend by continuing to grow year-on-year.”

That growth testifies to the operation’s ability to satisfy its customers – and to do so in such markets as security, fire, medical and electronics, where there is no toleration of second-best. A quick skim through the company’s files reinforces the point. One customer praises Fascia’s professionalism and extreme concern with product quality; another lauds its personal approach and quick turnaround; a third highlights its cost-effective service and its concern to enhance the customer’s competitive advantage.

Now there’s an exciting chance to extend that list of satisfied customers. Fascia has offered the reassurance of ISO approval for a decade, and last year saw it earning a further three-year ISO 9001:2000 accreditation. But that was quickly followed by the achievement of Underwriters Laboratories’ UL PGDQ2 status. The UL mark is the most widely recognised safety certification in the world, and it opens up the prospect of an estimated 15 per cent increase in overseas orders. “This is a significant achievement for Fascia Graphics,” observed founder and managing director Paul Bennett. “UL has been a product safety leader for over 100 years and is widely acknowledged for its safety standards, integrity and independence. With the growing emergence of the global market-place, we are finding opportunities to sell our products in many new markets.”

Turning opportunity into reality depends, of course, on the products themselves, and the company has a solid reputation for innovation in line with market needs. A recent example of this is its collaboration with MEDÆS to produce the first medical gas alarms with graphic overlays that inhibit the growth of potentially harmful bacteria. The overlays are manufactured from Autotex AM, a new hard-coated polyester film from MacDermid Autotype that incorporates Microban antibacterial protection. Independent testing has found that, among its valuable properties, this substrate has a 99 per cent kill rate against E-coli 0157 and MRSA.

Another recent step forward has been Fascia Graphics’ rapid prototyping service. The company recognised that design houses and engineering businesses often need professionally manufactured digital overlays or membrane keypads at very short notice for trade show prototypes or new product developments. So a nationwide service was launched to meet the requirements of such customers in no more than five days. In practice, as Bennett pointed out, the timescale can often be much shorter. “Subject to design, in some instances we have turned around digital overlays in just 24 hours.”

He spelt out the advantages on offer. “Taking an idea for a new product through to production can often be the start of a long and expensive journey. But companies are now finding that this need not be the case, since digital prototyping of membranes and overlays can reduce expenditure and operating costs, provide rapid time to market, and give the ability to maximise the latest technologies at an early stage in product development.”

Fascia Graphics’ research indicates that, as yet, 40 per cent of engineers don’t realise that such a fast service is possible. But as they become aware of the fact, the market will grow rapidly. Already those who are using the service are finding it offers a fast turnaround, allows product modifications before committing to a full set of artwork and tools, and saves their companies up to £5000 per annum. The prediction is for a boom in digital prototyping over the next five years.

As the business grows, its people will need to grow with it, and Fascia has committed itself to significant investment in their development. A new manager has been appointed to develop detailed training plans for all staff and to prepare the way for lean manufacturing. Central to this initiative is the introduction of opportunities to work for NVQ Level 2 in business improvement techniques. In a move consistent with the company’s aim of raising standards at all levels, Avon Vale (an organisation that specialises in working with manufacturing companies) has been appointed to provide in-house training. Starting with blocks of five people, the programme is designed to unfold across the whole company over a period of three years.

“This will allow staff to gain recognised qualifications, help to keep them motivated, promote their progression through the business, and raise levels of involvement,” said Anderson. “The NVQ training will allow us to introduce the principles and methodology of lean manufacturing.”

It’s a programme with its sights set firmly on the future, and it aligns well with Fascia’s confident outlook. “We believe that we’re leading the market,” stated Bennett, “and further expansion is planned, with investment in both people and equipment, in order to keep us at the forefront of developments.”