Listers investment in Fourjaw boosts productivity by 10%

Listers has improved productivity with FourJaw

Listers, one of the UK’s leading manufacturers of windows and doors, has reported significant gains in productivity and sustainability following the implementation of machine monitoring technology from FourJaw Manufacturing Analytics. The Staffordshire-based company, which produces over 3,000 windows each week, installed FourJaw’s plug-and-play monitoring system across six production lines to capture real-time data on machine utilisation, downtime, and energy consumption.

Since going live, the system has enabled Listers to improve productivity by 10% and increase machine utilisation by 12%, resulting in the manufacture of more than 250 additional windows per week without the need for extra equipment or personnel. These operational efficiencies have translated into more reliable delivery schedules and consistent product quality, while also supporting the company’s commitment to reducing its carbon footprint. By identifying opportunities to run machines more sustainably, Listers has already achieved a 10% reduction in wasted energy.

The data provided by FourJaw has become integral to Listers’ sustainability strategy, supporting its ISO 14001 and ISO 50001 certifications and helping to pinpoint areas of energy inefficiency. One such example involved a compressor that was consuming excessive power due to air leaks — an issue that, once resolved, led to notable monthly savings in energy costs and a measurable reduction in carbon emissions.

Minimising downtime
Looking ahead, Listers intends to expand its use of FourJaw technology to additional critical equipment and integrate it with its maintenance management system. This will allow real-time data to automatically trigger maintenance requests, minimising downtime and enhancing operational resilience.

The system has also empowered Listers’ workforce by providing operators with live data to diagnose issues quickly, reduce machine downtime, and develop new digital competencies. This integration of technology and teamwork is fostering a culture of continuous improvement across the business.

Stuart Pickersgill, director of manufacturing and operations at Listers, said: “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. 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.”

Chris Iveson, CEO at FourJaw Manufacturing Analytics, added: “Our work with Listers perfectly illustrates the tangible and immediate impact that smart technologies like FourJaw can have on manufacturing businesses. We are turning machine data into actionable insight fast and making it simple for manufacturers of all sizes to understand their operations, unlock significant productivity gains, reduce energy costs, and accelerate their journey toward a more sustainable future.”