ar18 doubles the size of its factory, becomes climate-smart and grows its CNC business.

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In 2015, ar18 was rapidly outgrowing its premises. With export sales booming, management wanted to double the size of the factory whilst still ensuring uninterrupted delivery of some of its largest orders to date.

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Pete Forest was appointed as CNC General Manager with P&L responsibility. He was to oversee a period of dramatic change: project manage the factory expansion, embed a culture of continual improvement and keep business as usual on track. Within a year, three new units were secured and fitted out with state-of-the-art manufacturing and climate smart technologies.

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Having secured planning and all necessary consents, the works included:

• Automated robotic warehouse

• 4 operator-controlled and 1 fully automated CNC machines

• Flood, fire and security systems

• 180kWp solar photovoltaic

• New grid connection, electrical fit out and LAN

• Dust extraction feeding a new biomass boiler

• Space heating throughout entire factory

• Spray booth ventilation with heat exchanger

• New secure and insulated doors and roof

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In parallel to the physical works, an improvement programme touched almost all aspects of the business:

• A culture of continuous improvement was embedded through techniques such as daily Kaizen time

• Working with supplier Pivale,  a new Drupal powered Content Management System was launched that better informed customers and vastly simplified the ordering process

• New commercial services were launched, meeting specific consumer demands and increasing margins

• An apprenticeship programme was launched with a local college

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Boris Johnson MP opened the new factory, to the delight of our middle-eastern clients. After 2 years of mentoring, the Production Manager was promoted to manage the now stable CNC business.