Leading manufacturer of windows & doors improves productivity by 10%

About Lister Windows

Listers is one of the UK’s largest manufacturers of windows and doors, producing more than 3,000 windows every week.

With a commitment to quality, sustainability, and customer satisfaction, Listers continues to invest in innovative technologies that strengthen its reputation as a trusted partner in the construction and home improvement industries.

How 12% higher machine utilisation enabled Listers to produce 250 additional windows per week using existing resources

“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."

Director of Manufacturing and Operations Stuart Pickersgill

 

Results

Project Objectives

As customer demand increased, Listers sought to:

• Boost productivity without adding new equipment or staff.

• Improve machine utilisation to maximise throughput.

• Reduce energy consumption and carbon emissions in line with ISO 14001 and ISO 50001 certifications.

• Empower operators with data to support faster problem-solving and a culture of continuous improvement.

Traditional monitoring methods couldn’t provide the real-time insight needed to achieve these goals, leading the business to explore new digital solutions.

Project Overview

To support its productivity and sustainability goals, Listers installed FourJaw’s plug-and-play machine monitoring system across six production lines at its Staffordshire factory.

The system provides real-time data on machine utilisation, downtime, and energy consumption, enabling the business to make data-driven decisions that directly improve output, efficiency, and sustainability performance.

"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.”

Director of Manufacturing and Operations Stuart Pickersgill

Results

Since implementing FourJaw, Listers has achieved measurable operational improvements:

• 10% productivity increase across its production lines.

• 12% higher machine utilisation, equating to over 250 additional windows produced per week using existing resources.

• A 10% reduction in wasted energy and energy savings of thousands of pounds per month were identified by removing inefficiencies, such as an air compressor that was leaking power.

• Lower carbon emissions, strengthening sustainability credentials and customer confidence.

• Workforce empowerment, with operators using live machine data to diagnose issues faster, reduce downtime, and build new digital skills.

For customers, this translates into more reliable delivery times, consistent high quality, and the assurance that their supply chain partner is actively reducing its carbon footprint. 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. 

Looking ahead, Listers plans to expand FourJaw’s use across additional equipment and integrate it with their maintenance management system to trigger automated maintenance requests in real time.