One of our long serving employees working on a PVCu frame

How lean manufacturing principles has led to success for Shelforce

Workers manufacturing uPVC frame

Lean manufacturing has its origins in the Japanese manufacturing industry. It is a systematic method that is designed to minimise waste without sacrificing productivity. For several years, we’ve been streamlining our manufacturing processes using our own version of a lean manufacturing method for our window and door products. We’ve gone from strength to strength ever since.

Improving our factory layout increased production efficiency by 759%

Enhancing our factory layout increased our output efficiency by 759% over three years! By improving productivity, we’re able to provide our high-quality windows and doors to a wider selection of customers. It has also allowed us to reduce lead times for our products so they are available much quicker than they were before.

As part of improving our factory layout, we reduced the number of factory units we were using from 3 to 2. Not only did this reduce overheads but it meant our machinery was situated closer together and subsequently easier to access. So, less time was wasted transferring materials between our various premises.

Reduced supply chain costs by 15%

By making improvements in our supply chain, we also managed to reduce our supply chain costs by 15%. We also did this without affecting our efficiency, so we could reinvest the money we saved here in other important areas of the business.

As a result of this and the other steps in our unique approach to lean manufacturing, we managed to…

Increase our sales revenue by 323%

This vast increase to our sales revenue – a whopping 323% – marks the culmination of all the changes we’ve made to the way we operate in the last few years and has confirmed our status as one of the top manufacturers and suppliers of uPVC and aluminium products in the UK.

However, despite our success, we’ve never strayed away from our core principles of providing high-quality windows and doors at competitive prices whilst challenging perceptions of disability. The majority of our workforce have some form of disability, making it one of the most diverse workforces in the world. And without their hard work and motivation, we wouldn’t have been half as successful as we have been over the past few years.

For more information on the products & services we provide here at Shelforce, please feel free to get in touch with us. We’re available to call on 0121 603 5262 or can be contacted online.


We have accreditations from a range of associations to prove the reliability of our service and the performance of our products.

Iso 9001 BSI ISO 14001 logo CE Mark Exova

Did you know...

We have an impressive history which stretches back to 1839 when we were a workplace for the visually impaired.

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