Maher Ltd, a Sheffield-based manufacturer of precision-machined components and high-performance alloys, has transformed its factory floor operations by deploying machine monitoring technology.
The FourJaw Manufacturing Analytics platform has given the company a significant boost in its drive for continuous improvement, energy savings, and enhanced productivity.
Previously reliant on manual job booking records to estimate production performance, Maher faced challenges in achieving accurate and timely insights into machine utilisation. In a bid to modernise and streamline its processes, the company installed FourJaw’s plug-and-play monitoring platform across critical production areas. This strategic move has enabled Maher to obtain a real-time, detailed view of machine performance and energy usage, laying the groundwork for data-driven decision making.
“FourJaw is simple, effective and works the way we do,” said Connor Blackshaw, Machining Supervisor at Maher. “It provides the performance visibility we need without overcomplicating things. The platform quickly became the oracle for our improvement initiatives, supplying the downtime reasons and baseline data for root cause analysis. We now see precisely what’s happening on the shop floor—even during lights-out shifts—and can immediately spot issues as they arise.”
The initial phase of the rollout began with benchmarking machine utilisation, cross-referencing FourJaw’s data with existing job booking records to establish a reliable starting point. With this clarity, Maher set an ambitious annual target of boosting machine utilisation by 5%. Astonishingly, since introducing FourJaw’s system in 2024, the company has already increased Overall Equipment Effectiveness (OEE) from 19% to 47% and raised Machine Utilisation from 29% to 46%.
Charlie Stothard, Automation and Process Improvement Manager at Maher, noted, “This technology is helping us move toward Industry 4.0. We can now work with directors to identify our strengths and weaknesses and plan improvements based on evidence, not assumptions. It gives us concrete data for cost control, budgeting, and further utilisation gains.”
FourJaw’s platform integrates seamlessly with machines of any age or brand, offering live dashboards for factory-floor staff and exporting data via API for advanced analysis. The technology’s plug-and-play nature made for a fast deployment and immediate results. “Our system empowers manufacturers to boost productivity and energy efficiency by providing complete visibility of their operations,” said Chris Iveson, CEO at FourJaw Manufacturing Analytics. “We’re proud to welcome Maher to the FourJaw family.”
Founded in 2020 as a spinout from the University of Sheffield’s Advanced Manufacturing Research Centre, FourJaw is now trusted by over 140 manufacturers across diverse sectors, including aerospace, automotive, energy, and food production.
Maher’s embrace of FourJaw’s technology showcases the power of digital transformation in UK manufacturing, setting a benchmark for industry peers seeking greater efficiency and competitiveness.