Wigan-based
C-TEC, a leading UK manufacturer of fire alarm and life safety systems is unlocking new levels of productivity and sustainability through digital transformation, supported by the
Made Smarter programme.
C-TEC, headquartered in Wigan, has invested £40,000 in replacing its manual, paper-based inventory processes with a cloud-based warehouse management system. The move has enabled real-time stock control, significantly improving operational efficiency and accuracy across its manufacturing operations.
The project was backed by a £20,000 grant from Made Smarter, the Government-supported initiative aimed at helping SME manufacturers adopt new technologies. As a result, C-TEC has increased warehouse productivity by 25%, eliminated despatch errors, and removed paper waste — advancing its environmental goals and ESG credentials.
Peter Butterworth, C-TEC manufacturing operations director, said: “Made Smarter didn’t just help us identify a problem, they gave us the confidence and support to act on it. Their backing enabled us to accelerate our digital transformation, eliminate inefficiencies, and build a smarter, more scalable operation ready for the future. It has been a genuine turning point for our business.”
World-class life safety systemsFounded in 1981 above a restaurant in Wigan, just a few doors down from Dave Whelan’s first sports shop, C-TEC has grown from a small family-run business into a £25 million manufacturer of world-class life safety systems. Today, it exports to over 80 countries and employs 195 staff at its headquarters, where it produces a wide range of open — protocol fire detection and alarm systems, evacuation alert systems, disabled refuge systems, and hearing assistance products. A dedicated R&D centre in nearby Mawdesley houses 25 engineers focused on product innovation.
The Grenfell Tower tragedy marked a turning point for the industry and for C-TEC, prompting the company to accelerate development of smarter, connected systems with enhanced monitoring and evacuation capabilities. This innovation has opened doors to major projects in high-rise buildings, stadia, hospitals, hotels, and shopping centres.
Despite sustained investment in systems, people, and processes, C-TEC identified its warehouse operations as a bottleneck. A digital transformation workshop delivered through Made Smarter revealed that high product variety and volume—around 9,000 part numbers across finished goods, sub-assemblies, and raw materials—combined with manual stock handling and paper-based inventory control, were contributing to inefficiencies and errors.
Mr Butterworth continued: “We have got around 9,000 part numbers across finished goods, sub-assemblies, and raw materials. It is a complex operation. Too much of our warehousing was manual, error-prone, and paper-heavy. We needed to improve traceability, stock control, and reporting to support future growth.”
To address these challenges, C-TEC implemented IFS’s WaDaCo system, fully integrated with its ERP (enterprise resource planning) platform. The solution digitalises warehouse processes from goods-in to dispatch, using mobile barcode scanners and PDAs to enable real-time inventory updates. Manual errors and paper-based tasks have been virtually eliminated, and the system is designed to support future supply chain integration.
New jobs and expansionThe results have been immediate. Warehouse productivity has risen by 25% without increasing headcount, and the company now saves the equivalent of nearly four mature trees’ worth of paper annually. Four new warehouse roles are expected to be created over the next three years as the business scales.
A key strength of the project has been the involvement of staff across the company, with 14 employees trained and upskilled in digital tools. Mr Butterworth said: “It’s not just about software, it’s about culture. Our people are now more confident, faster, and equipped with real-time data.”
Alongside Made Smarter’s support, C-TEC is also investing in automation and advanced manufacturing technologies to prepare for its next wave of disruptive products, including the award-winning CAST-PRO. Donna Edwards, programme director for Made Smarter Adoption North West, said: “C-TEC is a fantastic example of how digital transformation, driven by ambition and supported by the right guidance, can unlock productivity, sustainability, and future growth. Their journey shows that even well-established manufacturers can take bold steps to modernise and future-proof their operations.”
Since its launch in 2019, Made Smarter has engaged with thousands of manufacturers, offering grant funding, impartial technology advice, leadership and skills training, and digital internships to help transform UK manufacturing.