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.
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.
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.
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.