Press Releases

All the Right Moves

Experience tells us that some building products manufacturers use the upheaval of moving to new premises as an excuse for late deliveries and the failure to hit their targets for launching new ranges. Duraflex, by contrast, not only completed the consolidation of its diverse operations onto a single site near Cheltenham with smooth efficiency, but the change has also proved to be a catalyst for a series of improvements currently being passed on to its fabricator network.

The systems company already had a reputation for product innovation, but is now building on this by further improving product reliability, introducing new design technology and cutting waste.

One of the immediate benefits of the relocation, aside from commissioning state-of-the-art extrusion and other production facilities, was the ability to accurately monitor waste. This might not sound like the most dramatic of developments but the avoidance of such problems as contamination has seen yield loss driven down to industry leading levels. While this is well below the industry average, the target is a miserly one per cent, which should benefit all involved.

The system house has meanwhile passed the landmark figure of offering its clients 50 different product lines, and every one of the new products launched over the past three years has been brought out on schedule and exceeded its sales targets.

Energy usage has similarly been cut through the adoption of new manufacturing practices and non-productive transport usage has been reduced as products and materials are no longer hauled from one site to another.

Importantly there is a recognition within the management team that product developments should not simply be added to the range for the sake of attracting custom, but that their technical accuracy and viability is essential to maintaining the brand's reputation.

Ray McGrady, Technical Director of Duraflex comments: "We recognise that all of the design criteria have to be right for our fabricators, the installers, and end user as well as for Duraflex as the system extruder. For this reason we keep all of the design work within the group and have introduced new technology to assist with prototyping."

This involved purchasing the sort of CAD modelling equipment more commonly associated with the automotive industry. All prototypes are now available in a resin material within four days of the computer file being approved.

This enables the technicians in the factory to check such aspects of performance as the fit for reinforcement and ease with which beads can be installed. In fact Duraflex's investment on product testing now exceeds £70 K per year and is set to grow further to meet industry and regulatory requirements.

Ray continues: "Duraflex has wind load and dead load testing programmes to help in the design and specification process; while we also retain an external structural survey specialist to monitor the advice given to fabricators.

"Also Duraflex has always taken the approach of waiting to see the final version of any new legislation, rather than reacting to part information and thereby confusing its customers. One bulletin issued at the end of the discussion and drafting process gives all the necessary -and accurate- advice."

Crucially, Duraflex's in-house testing is backed up by a comprehensive programme of independent evaluation with all products carrying the appropriate BSI, British Board of Agrement or Secured by Design certification. Indeed its patio doors are being progressed through BBA certification.

Duraflex has also invested a lot of effort in system integration. This reduces stockholding for fabricators and simplifies the production process as the same hardware, reinforcement and beads are compatible with the widest possible selection of products.

Ray concludes: "One increasingly important aspect to the service we offer is that specification projects can be brought into the factory by our commercial representatives. Duraflex will then produce a specification for the fabricator to use for tender. With all of the money and effort we have invested in streamlining our production and distribution process, as well as product development, fabricators now recognise Duraflex as one stop shop for all their profile, production and even hardware needs."

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