UK INNOVATIONS: British window maker boosts output and cuts energy waste with FourJaw analytics

Leading UK window and door manufacturer Listers has demonstrated how a targeted investment in smart technology can deliver a rapid and significant boost to both the bottom line and sustainability targets. The Staffordshire-based giant, which produces over 3,000 windows weekly, has seen a host of operational improvements since deploying FourJaw Manufacturing Analytics.

Listers installed FourJaw’s “plug-and-play” machine monitoring system on six production lines, providing real-time data on machine utilisation, downtime, and energy consumption. The results have been striking: productivity has improved by 10% and machine utilisation is up 12%. This uptick means Listers can now produce over 250 additional windows each week using its existing workforce and assets, translating to more reliable delivery times for customers.

Crucially, the investment is proving its worth in the drive for a greener operation. By identifying opportunities to run machines more sustainably, the firm has achieved a 10% reduction in wasted energy. FourJaw has already helped Listers reduce its carbon emissions and save thousands of pounds a month in energy expenditure, including flagging an air-leaking compressor that was wasting power. This machine-level energy data is now a key component in supporting its ISO 14001 and ISO 50001 certifications.

Stuart Pickersgill, Listers’ Director of Manufacturing and Operations, hailed the system as the “heartbeat of the business,” enabling a proactive approach to continuous improvement. The real-time data not only benefits processes but empowers the workforce, helping operators quickly diagnose issues, reduce downtime, and develop new digital skills. Listers now plans to expand the system across other critical equipment and integrate it with its maintenance management to trigger automated requests, further strengthening its operational resilience in a competitive marketplace.

Why This Matters: This investment showcases a vital path for UK window manufacturers to achieve simultaneous 10% gains in productivity and sustainability, proving smart factory tech has an immediate, essential ROI. Smart factories through technology, including AI, will drive product quality by helping to limit re-makes and errors which will drive overall efficiencies.