In manufacturing, small inefficiencies add up to big losses. Whether it's hidden downtime, underused machines, or misdirected training efforts, the lack of real-time factory floor visibility often prevents manufacturers from reaching their full potential.
Fortunately, technologies like FourJaw provide a simple yet powerful way to collect and act on machine data, supporting continuous improvement, improving asset utilisation, removing production bottlenecks, and increasing capacity. And the best part? It doesn’t require months of complex IT integration.
In this blog, we’ll explore how manufacturers across sectors use FourJaw to deliver measurable improvements on the factory floor—and what lessons you can take from their successes.
01: Visibility Is the First Step to Improvement
Industry context: Studies show that the average machine utilisation in UK factories sits at only 60–70%, meaning up to 40% of capacity goes unused each day.
Case Study: AMS
Architectural & Metal Systems (AMS) installed FourJaw in December 2023 to get a clear, objective view of machine performance. They discovered utilisation was just 39.8%—far below industry averages—and used that insight to:
- Shift to better-balanced working patterns
- Cut an average of 20 minutes’ downtime per machine, per shift
- Increase utilisation to 52.9% within three months
These improvements translate to a 19% rise in machine productivity and €30,000 in annual efficiency and sustainability savings.
02: Using Data to Drive Continuous Improvement
Guesswork makes root-cause analysis slow and unreliable. With FourJaw, every second of downtime is classified by reason, so you can tackle the biggest losses first.
Case Study: Fernco
Fernco replaced days-worth of manual logging with FourJaw’s automated capture on its injection-moulding machines. In just weeks, they:
- Pinpointed true downtime causes (not just spindle movement)
- Gained real-time alerts, slashing response times to issues
- Achieved a 10% increase in production efficiency
This data-driven clarity gave Fernco the confidence to set and hit realistic utilisation targets.
03: Focusing Training Where It Matters Most
Operators are your front line, but training them effectively requires knowing where skill gaps cause the most downtime.
Case Study: Vernacare
At its Worksop site, healthcare-product maker Vernacare used FourJaw to monitor its dry-wipe lines. By analysing downtime patterns, they:
- Removed all production backlogs
- Cut machine downtime by 20%
- Nearly eliminated rush jobs and overtime
Armed with precise data on which machines and operations needed support, they improved on-time delivery and reduced stress on their team.
04: Maximising Asset Utilisation and Justifying Investment
Before buying new machines, you need to be sure you’re fully leveraging your current fleet—data makes that case.
Case Study: Hydrafeed
Hydrafeed’s 19-machine CNC shop lacked visibility into workload balance. After installing FourJaw on 14 machines, they:
- Established a clear utilisation benchmark
- Boosted overall machine utilisation by 30%
- Identified £17,000 of annual energy savings within weeks
These insights meant they met rising demand without new capital outlay, and reduced energy costs at the same time.
05: Removing Production Backlogs and Increasing Capacity
When orders stack up, real-time data helps manufacturers identify bottlenecks and unlock hidden capacity, without hiring or buying new equipment.
Case Study: Armac Martin
Armac Martin, a Birmingham-based manufacturer of luxury brass cabinet hardware, faced production capacity constraints with demand outstripping supply, leading to production backlogs and increased lead times. By implementing FourJaw's machine monitoring software, they:
- Achieved a 14% uplift in machine utilisation, increasing from 21.7% to 35.8% in their Turning section.
- Were able to produce 65% more products in the same timeframe.
- Identified under-utilised machinery, leading to the sale of redundant equipment and investment in more appropriate machines.
- Shifted focus from subcontract work to their own product lines, enhancing profitability.
This strategic use of real-time data allowed Armac Martin to remove production backlogs and significantly increase capacity without the need for additional shifts or headcount.
Conclusion: Small Tech, Big Impact
These stories show that you don’t need a multi-million-pound ERP overhaul to start continuous improvement. Although a simple, scalable tool like FourJaw is used by global manufacturers and SME manufacturers alike, enabling them to:
- Reveal hidden waste
- Drive data-led decisions
- Focus on training and maintenance where it counts
- Free capacity and reduce capital risk
- Improve sustainability
Ready to uncover your factory’s hidden potential? Book a demo and see what you’ve been missing.
