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.
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.
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:
These improvements translate to a 19% rise in machine productivity and €30,000 in annual efficiency and sustainability savings.
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.
Fernco replaced days-worth of manual logging with FourJaw’s automated capture on its injection-moulding machines. In just weeks, they:
This data-driven clarity gave Fernco the confidence to set and hit realistic utilisation targets.
Operators are your front line, but training them effectively requires knowing where skill gaps cause the most downtime.
At its Worksop site, healthcare-product maker Vernacare used FourJaw to monitor its dry-wipe lines. By analysing downtime patterns, they:
Armed with precise data on which machines and operations needed support, they improved on-time delivery and reduced stress on their team.
Before buying new machines, you need to be sure you’re fully leveraging your current fleet—data makes that case.
Hydrafeed’s 19-machine CNC shop lacked visibility into workload balance. After installing FourJaw on 14 machines, they:
These insights meant they met rising demand without new capital outlay, and reduced energy costs at the same time.
When orders stack up, real-time data helps manufacturers identify bottlenecks and unlock hidden capacity, without hiring or buying new equipment.
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:
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.
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:
Ready to uncover your factory’s hidden potential? Book a demo and see what you’ve been missing.