Smart Machine Monitoring Drives Productivity and Sustainability Transformation
Listers, one of the UK’s largest manufacturers of windows and doors, has achieved significant productivity and sustainability improvements in its manufacturing operations following the adoption of machine monitoring technology from FourJaw Manufacturing Analytics.
Listers, who produce more than 3,000 windows a week, decided to install FourJaw’s plug-and-play machine monitoring system on six production lines in its factory in to gain real-time data on machine utilisation, downtime and energy consumption. Since going live, the data has helped Listers improve productivity by 10% and increase machine utilisation by 12%, enabling it to produce more than 250 additional windows each week using its existing assets and workforce.
For customers, this translates into more reliable delivery times, consistent quality, and the assurance that their supply chain partner is actively reducing its carbon footprint. Listers has already achieved a 10% reduction in wasted energy by using FourJaw to identify opportunities to run its machines more sustainably. These improvements strengthen Listers’ operational resilience and support customers’ own sustainability commitments, making Listers a partner of choice in a competitive marketplace.
FourJaw’s technology has also become a key component of Listers’ sustainability initiatives, providing machine-level energy data to support its ISO 14001 and ISO 50001 certifications and highlight machines and production processes where energy is potentially wasted. FourJaw has already helped Listers reduce its carbon emissions and save thousands of pounds a month in energy expenditure by identifying a compressor that was using more power than it should due to air leaks.
Listers plans to expand its use of FourJaw to gather data from other critical pieces of equipment in its factory and to integrate FourJaw with its maintenance management system, using real-time data to trigger automated maintenance requests the moment a machine goes down.
The system also empowers Listers’ workforce, giving operators real-time data that helps them quickly diagnose issues, reduce downtime, and develop new digital skills. By integrating technology with teamwork, Listers is building a culture of continuous improvement that benefits both people and processes.
“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. In just a few short months, FourJaw has changed the way decisions are made at Listers and delivered productivity and sustainability gains that are already saving us thousands of pounds a week” commented Stuart Pickersgill, Director of Manufacturing and Operations at Listers.
“Our work with Listers perfectly illustrates the tangible and immediate impact that smart technologies like FourJaw can have on manufacturing businesses. 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” stated Chris Iveson, CEO at FourJaw Manufacturing Analytics.
For more information: www.fourjaw.com
