Bridgwater manufacturer demonstrates real pedal power

9th Jan 2007

Thorn Cycles, a Bridgwater-based business with a global customer base, is preparing itself for a bumper year following strategic input from the South West MAS.

The growing desire across the world for specialised bikes, tandems, touring bikes and commuter bikes has seen Thorn Cycles grow from a small shop, supplying and maintaining cycles for the local cycling community, into a large business, catering for the discerning UK and increasingly global touring and tandem market.

As with many small businesses, however, the manufacturer’s processes and systems were not, until recently, ready for the demand created by the internet and the company’s growing reputation in the market.

The founder and managing director, Robin Thorn, contacted the South West MAS with concerns about bottlenecks within the business and how to get the best out of his team of 30 employees. South West MAS specialist, Charles Hill, recommended a multi-faceted approach whereby employees would be introduced to lean manufacturing techniques and a culture of continuous improvement.

Meanwhile, leaders within the company were encouraged to take part in the South West MAS’ Strategic Management Programme (SMP). SMP aims to help SME manufacturers embrace knowledge-intensive, skilled manufacturing and create new opportunities for growth. It combines a strategic review and sustained implementation support to equip management teams with the tools they need to develop and drive business strategy forward.

Robin Thorn explains: “It was fascinating seeing how the South West MAS specialists worked. They videoed our production line and identified areas where we were wasting time and energy. They led workshops with our teams and really motivated us to organise our processes and communicate more effectively throughout the business.

“Having had poor experiences to date with other semi-government bodies, I was surprised by how effective the South West MAS was at identifying issues and setting up solutions. This is in no small part down to the individuals sent to assist us. Everyone that we worked alongside from the South West MAS had years of experience working in the manufacturing industry. I would have no hesitation in recommending them to any business serious about improvement.”

As a result of advice from the South West MAS, the company has consolidated its two workshops into one and freed up valuable space for new business activity. Productivity on the assembly line has also increased by 30 per cent. In addition, Thorns has created a specialist sales team to focus on dealing with customer order fulfillment and to lead to improved sales conversion.

Adrian Knight, IT manager at Thorns, says: “When you step back and think, we have made so many improvements in the last nine months. If we had not taken part in the Strategic Management Programme, we would still be doing the same things that we did last year. Some of the biggest changes are in how we structure the business, which is starting to show significant benefits. Simple changes such as creating area supervisors with responsibilities for specific activities can have dramatic effects.”

Charles Hill, South West MAS specialist, comments: “It has been a pleasure to work with Thorn Cycles and watch them implement the lessons they have learnt through lean workshops and the strategic review. They have significantly increased productivity and boosted morale amongst the workforce as a result.”

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