Case Study: How Qualkem Unlocked New Productivity Levels Through Support from the Productivity Improvement Programme

“What Matt did in 1 hour was a game changer!” Ivan, Managing Director

The Need for Change

At Qualkem Ltd, a well-established manufacturing business in Cheshire, things were running smoothly, but the management team knew that there were areas in the business that could be improved upon. With over 50 years of experience supplying products across various sectors—ranging from portable toilets and leisure to healthcare and veterinary—the team had a wealth of knowledge. But like many businesses, they faced challenges in scaling up and streamlining operations.

The Challenges: Identifying the Bottlenecks

Ivan Anketell, Managing Director of Qualkem, along with his dedicated team, pinpointed a

few critical areas that needed improvement:

• They were installing a second, more automated bottling line but needed to optimise its layout and product flow.

• The shopfloor and warehouse organisation was impacting on efficiency and safety.

• There was a lack of transparency in tracking production progress and quality metrics on the shopfloor.

• Too much reliance on paper-based systems, which slowed down operations and made data management cumbersome.

The Solution: Collaborative Problem-Solving

Earlier this year, Ivan signed up for a Productivity Improvement Programme (PIP)

workshop held at AMRC Cymru, where he met Matt Booth, AMRC Cymru’s Sustainability

Lead. Funded by the UK Government through the UK Shared Prosperity Fund, the

Productivity Improvement Programme aims to help manufacturers solve challenges and

enable growth. The programme is delivered by Cheshire East Council in partnership with

BIC Innovation and AMRC Cymru, part of the University of Sheffield Advanced

Manufacturing Research Centre (AMRC).

Following their initial meeting, Matt visited Qualkem where they discussed the company’s

challenges and to tackle them. In Ivan’s words “What Matt did in 1 hour was a game

changer!”

Qualkem’s journey with the Productivity Improvement Programme had begun, and since

attending that workshop, here’s how Ivan, his team and our industry experts have gone on to tackle those bottlenecks:

1. Optimising the Bottling Line Layout

Matt worked closely with the team to evaluate different layout options for the new bottling

line. They examined everything from product flow and operator positions to future expansion possibilities. After an in-depth discussion, everyone agreed on the best layout, with plans for future alterations if needed. This collaborative approach not only ensured an efficient setup but also laid the groundwork for future growth.

Tip: When planning a new production line, don’t just focus on the immediate needs. Think

about how the layout might need to adapt as your business grows. Involve your team in the

discussion—different perspectives can lead to better solutions.

2. Improving Product Flow

One of the standout suggestions was implementing a high-level pumping system to move

chemicals directly from storage tanks to the bottling line. This idea hadn’t occurred to the

team at Qualkem before but offered several benefits: freeing up valuable floor space,

reducing forklift traffic, and enhancing overall safety. Although there were logistical questions to consider, this new perspective opened up possibilities for a more streamlined operation.

Tip: Sometimes, the most effective solutions are the simplest ones you hadn’t considered.

Bring in fresh eyes to challenge your existing processes—they might see something you’ve

overlooked.

3. Streamlining Warehouse Operations

The shopfloor and warehouse organisation were also areas for potential improvements.

Matt’s advice was straightforward but effective: a thorough clean-up and reorganisation. The team would remove all tools and equipment from the area, only bringing back what was

necessary for daily operations. This strategy would not only declutter the space but also instil a culture of organisation and efficiency.

Tip: A well-organised workspace can help boost productivity. Take a weekend to declutter,

and make sure everything has a designated place. This step can lead to surprising

improvements in your workflow.

4. Enhancing Data Visibility

One of the key takeaways from Ivan’s visit to AMRC Cymru was the value of a paperless

shop floor. Inspired by what he saw, Ivan and his team are now working towards

implementing digital display screens to monitor production progress, display upcoming

production schedules and quality metrics in real time. This shift will provide the entire team

with better visibility into ongoing and upcoming tasks, helping to prevent bottlenecks and

improve decision-making.

Tip: Going digital doesn’t have to be complicated. Start small, like setting up a few digital

screens to display key metrics. As you see the benefits, you can expand the system to cover more areas of your operation.

The Results: A Journey Just Beginning

While it’s still early days, the changes at Qualkem are already setting the stage for a more

efficient and scalable operation. The company has just embarked on this intensive support

journey with the Productivity Improvement Programme, but the initial steps have already

shown that quick wins are possible and can make a significant difference.

“Through my close working relationship with the Cheshire East Business Support Hub, I was

signposted to the Productivity Improvement Programme, the launch of which aligned

perfectly with my production expansion plans. Whilst the state-of-the-art Advanced

Manufacturing Centre is mind blowing, the Programme content inspires next level affordable

thinking. Matt’s follow up site visit has transformed my thinking on production line design,

production efficiencies and operational culture across the business.” Ivan, Managing

Director

Why You Should Join the Productivity Improvement Programme

If you’re a manufacturing business in Cheshire East, Qualkem’s story shows that you don’t

need to overhaul your entire operation or spend thousands of pounds to see improvements.

Sometimes, a few targeted changes, supported by expert advice, can lead to meaningful

progress.

The fully-funded Productivity Improvement Programme offers practical, actionable insights

tailored to your specific challenges, at no cost to participants—helping you unlock your

business’s full potential.

Final Thought: Don’t wait until your challenges become roadblocks. Reach out, get involved

in the Productivity Improvement Programme, and see how quick wins can set you on a path

to sustained growth.