Emplas investment delivers stronger service for installers

With installers under more pressure to maintain margins, Emplas says working with the right fabricator has never been more crucial.

But while product quality and customer care are essential, there can be more to good service than meets the eye.

In recent years, Emplas has undertaken one of the most significant operational improvement programmes since it was founded, investing heavily in its manufacturing infrastructure.

The addition of a new 25,000ft2 manufacturing facility, three years ago, not only created a dedicated composite door facility but also freed up valuable space in its pre-existing 57,000ft2 factory, sparking an extensive overhaul that has delivered enviable results for the Wellingborough-based fabricator.

“It started off in 2023 when we decided to purchase ‘Emplas 2’ and move our ancillary composite door and patio department to open space in ‘Emplas 1’,” says Dawid Hajduk, Operations Support Leader at Emplas.

“Since then, we’ve reorganised every part of the factory. We’ve moved pretty much every machine, and redone the layout to help improve process flows, quality and efficiency.

“We are really proud to say that these changes have increased our output by over 20% in the last couple of years.”

Although it might sound simple, these impressive gains were not so easily achieved.

Instead, they required detailed planning around workloads, identifying small windows of opportunity to move machinery, reinstall equipment and maintain production in an environment where protecting customer service was paramount, and downtime was not an option.

“The key challenge around reorganising the factory was that we couldn’t stop it,” said Dawid.

“We had to fulfil customer deliveries, on time and in full, whilst moving machines from one side of the factory to the other.

“We did it by planning extensively. Looking at workloads and understanding where we would have a gap that would allow us to move the machines, get them in place, set them up correctly, and still be able to achieve customer delivery.”

For installers, this targeted behind-the-scenes activity translates directly into improved service.

Greater manufacturing efficiency equates to increased production capacity, better consistency and stronger operational resilience, providing customers with a fabricator partner that is well-equipped to support future growth.

Reflecting a wider philosophy within the business, all investments are made with the aim of creating tangible benefits for Emplas customers through improved reliability, greater flexibility and increased manufacturing capability.

“Everything we do, is designed to ultimately improve the service we offer to our customers,” says Dawid.

“The market is challenging at the moment, so installers need to work with progressive suppliers who are willing to put in the infrastructure and invest in the future, rather than standing still.

“Businesses that improve efficiency and strengthen operations are better positioned to maintain service levels, support growth opportunities and respond to changing consumer demands.”

The extensive factory reorganisation undertaken at Emplas is said to demonstrate exactly that approach.

By investing in additional facilities, redesigning production processes and continuously improving manufacturing efficiency, the company has created a stronger, more resilient operation capable of supporting customers not just today, but in the years ahead.

While much of the work has taken place behind-the-scenes, the benefits are said to be clear to see.

“It’s a bit like a swan on the water,” added Dawid. “Everything appears to be calm and serene but there’s a lot of paddling going on underneath and it’s delivering the best results for our customers.”

For more information about Emplas, visit: Window Manufacturers & Window and Door Suppliers | Emplas