For Dorking-based injection moulder Broanmain Plastics, it’s business as normal … with a few slight adaptations to workforce patterns. But when it comes to production, at this moment in time the company is still very much open for business, assisting OEM customers who need to pull forward on orders or ramp up production and assembly of specific components, most destined for use in medical devices, reassures Managing Director Jo Davis.
Taking the pandemic seriously, the management team is adhering to government and Public Health England guidance regarding social distancing and protecting workforce safety in workspaces. With the situation continuing to evolve day-by-day, Jo points out that during this fog of uncertainty, normal is being reshaped – potentially indefinitely in the manufacturing landscape.
“The urgency of the situation cannot be underplayed. Flexibility is now the norm. And day-by-day, manufacturers across the UK are adjusting to what at best can be described as the ‘next normal’. Balancing the safeguarding of lives with the protection of livelihoods is imperative,” comments Jo. Like many factories, working from home is not an option. In order to ensure staff can balance family time with work, Broanmain has extended it production opening times by two and half hours, introduced split-shift flexible working patterns, providing cover between 6am and 5pm, and closed the factory on Friday’s.
Already, this has enabled Broanmain to respond swiftly to order increases and turn projects around in less than 48 hours. “As we are seeing first hand, this is all feasible providing a customer has the tooling and we can source the polymer materials,” highlights production manager Thomas Catinet.
Broanmain reports that new projects requiring tooling design and testing have, rightly so, been put on pause. Thomas explains: “As we are seeing with the ventilator challenges, even with fast track approvals, it takes time – often two to three months – to move from concept to accreditation and then production.”
Another benefit of the remote working is OEMs are now giving future projects their full attention, and are eager to discuss the scope and feasibility. A number have also been discussing supply chain risks and the different choke points when reliant on production hubs the other side of the globe. To help mitigate future risks, reshoring is likely to escalate, adds Jo: “This virus has exposed our global vulnerabilities and interdependencies. I imagine the supply chain dynamics may shift again. Although an uncertain and stressful time for everyone in every business, it can be a good time to re-evaluate supply chain options and speak to domestic companies about how they can assist.”
Common purpose
Having combined manufacturing muscle can clearly speed matters up. And it’s here where larger moulders are best placed to ramp up component production. “Realistically, building a tool and then getting it approved is beyond the scope of most moulding SMEs as it’s a high cost investment and would need to met set specifications,” exclaims Thomas. He notes that their efforts are best served supporting existing medical, electronic, optical and building control OEMs.
Another vulnerability exposed by Covid-19 is the shortage of skills in plastic processing. Establishing new behaviours with regard to knowledge sharing is imperative, stresses Jo. “Sourcing skilled staff can be challenging at the best of times. Sharing personnel tends to go against the grain of how we work as an industry. Clearly, this needs to change. Being able to share expertise and specific skill sets with other manufacturers is a lesson we can all take away from this pandemic.
Like everyone across the globe, manufacturers and moulders are all facing this crisis together. Rather than just trying to protect our own island, coming together as a business community can help to strengthen our resilience. And this in turn benefits customers.”
