Listers has improved productivity by 10% and increased machine utilisation by 12% after deploying machine monitoring technology from FourJaw Manufacturing Analytics across its Staffordshire manufacturing site.
The window and door manufacturer, which produces more than 3,000 windows each week, installed FourJaw’s plug-and-play monitoring system across six production lines to gain real-time visibility into machine utilisation, downtime and energy consumption. The company says the improvements have enabled it to manufacture more than 250 additional windows per week using its existing workforce and assets.
Listers has also used the system to support sustainability initiatives, achieving a 10% reduction in wasted energy by identifying inefficiencies in factory operations. According to the company, FourJaw helped uncover excessive power usage caused by air leaks in a compressor system, contributing to lower carbon emissions and saving thousands of pounds each month in energy costs.
The data generated by the platform is also supporting the manufacturer’s ISO 14001 and ISO 50001 certification efforts by providing machine-level energy insights and highlighting areas of potential waste.
Stuart Pickersgill, Director of Manufacturing and Operations at Listers, said the technology had transformed operational decision-making within the business.
“FourJaw has been a breath of fresh air for Listers. It has become the heartbeat of the business, enabling us to take a proactive and targeted approach to continuous improvement that benefits our people, customers and bottom line.”
– Stuart Pickersgill.
Listers plans to expand its use of the platform to additional factory equipment and integrate the data into its maintenance management systems, allowing automated maintenance requests to be triggered when machines go offline.
Chris Iveson, CEO of FourJaw Manufacturing Analytics, said the project demonstrated how manufacturers can use machine data to drive both productivity and sustainability gains.
“We are turning machine data into actionable insight fast and making it simple for manufacturers of all sizes to understand their operations, unlock significant productivity gains, reduce energy costs, and accelerate their journey toward a more sustainable future.”
– Chris Iveson.
Founded in 2020 as a spinout from the Advanced Manufacturing Research Centre (AMRC), FourJaw provides machine monitoring software to manufacturers across sectors including aerospace, automotive, energy and food production.
For more articles like this, visit our Digitalisation channel
