Big Bear Plastic Products, a thermoforming specialist based in Droitwich, Worcestershire, is carving a distinctive path in UK manufacturing through material innovation, digital transformation and a strong focus on people. Managing Director Emma Hockley leads the 80–100-strong team, producing large and complex plastic components used across a variety of sectors — from caravan bumpers and parts for agricultural and construction vehicles to aeroplane seats and even garden ponds.
The company is also navigating the industry-wide shift toward digitalisation. Big Bear recently implemented a new ERP system with support from WMG and Made Smarter, integrating operations without disruption to customers. The next step, Emma says, is exploring the practical application of AI to enhance efficiency and support employees.
Challenges remain familiar across the sector: supply chain volatility, recruitment difficulties, increasing regulatory pressures and rising operational costs. And Emma notes that many SMEs feel overlooked in the government’s Industrial Strategy, and upcoming policy changes — such as the Employment Rights Bill — risk placing additional strain on small manufacturers who are already committed to supporting and valuing their workforce.
Reflecting on her own journey as a woman leader without a manufacturing background, Emma acknowledged early imposter syndrome but emphasised that success stems from building a strong, aligned team. Looking forward, Big Bear’s roadmap focuses on growth, deeper supplier collaboration and accelerating material innovation — building on the solid operational foundations laid in recent years.
