C-TEC sparks smarter growth phase thanks to digital overhaul

Based in Wigan, C-TEC has invested £40,000 to replace manual, paper-based inventory processes with a cloud-based software solution, which enables real-time stock management and dramatically improves efficiency and accuracy.

C-TEC has actively increased productivity by 25%, eliminated dispatch errors and cut out paper waste, in turn supporting the company’s sustainability goals.

The project has been underpinned by a £20,000 grant from Made Smarter, laying the foundations for a scaling of operations, the introduction of new and disruptive fire safety products and the creation of four new jobs.

Confidence and support

Peter Butterworth, operations director for manufacturing at C-TEC, informed Fire Safety Matters: “Made Smarter didn’t just help us to identify a problem. They gave us the confidence and support to act on it. That backing enabled us to accelerate our digital transformation, eliminate inefficiencies and build a smarter and more scalable operation ready for the future. It has been a genuine turning point for our business.”

C-TEC began life above a restaurant in 1981, just a few doors down from Wigan entrepreneur Dave Whelan’s first sports shop. Fast-forward four decades and the small, family-run business has grown into a £25 million manufacturer of world-class life safety systems, exporting to over 80 countries.

From headquarters, C-TEC’s 195-strong team manufactures a vast range of open-protocol fire detection and fire alarm systems, evacuation alert systems, call systems, disabled refuge systems and hearing assistance systems. Just a few miles up the road in Mawdesley, the company operates a dedicated R&D Centre that plays host to 25 engineers driving product innovation.

The Grenfell Tower tragedy was a turning point for the fire industry, prompting C-TEC to accelerate the development of smarter and connected systems with enhanced monitoring and evacuation capabilities. This innovation has opened doors to major projects involving high-rise structures, stadiums, hotels, hospitals and Shopping Centres.

Warehouse modernisation

In parallel with sustained growth through investment in systems, people and processes, C-TEC recognised that its warehouse capabilities needed modernisation. A digital transformation workshop delivered through the Made Smarter Programme revealed key challenges: high product variety and volume, a reliance on manual stock handling and paper-based inventory control processes were contributing to errors, inefficiencies and bottlenecks.

“We have around 9,000 part numbers across finished goods, sub-assemblies and raw materials,” affirmed Peter Butterworth. “It’s a complex operation. Too much of our warehousing was manual, error-prone and paper-heavy. We needed to improve traceability, stock control and reporting to support future growth.”

As such, C-TEC implemented IFS’ WaDaCo system, fully integrated with its ERP, to digitise warehouse processes from goods-in to despatch. Mobile barcode scanners and PDAs now enable real-time inventory updates, eliminating manual errors and paper-based tasks. The system also supports future supply chain integration.

Digital adoption has delivered immediate results, boosting warehouse productivity by 25% without increasing headcount and virtually eliminating manual errors. By scrapping printed pick lists, C-TEC now saves nearly four mature trees’ worth of paper on an annual basis, advancing its own ‘Net Zero’ goals and Environmental, Social and Governance credentials.

Company-wide involvement  

A key strength of the project has been company-wide involvement, with 14 employees trained and upskilled in digital tools. “It’s not just about software,” stated Butterworth. “It’s about culture. Our people are now more confident, faster and equipped with real-time data.”

WaDaCo is future-proofed to support growth, enabling C-TEC to scale output, maintain quality and introduce new products. Over the next three years, the project is expected to create four new warehouse roles.

Alongside Made Smarter’s support, C-TEC is also investing in automation and advanced manufacturing to prepare for its next wave of disruptive products, including the award-winning CAST-PRO.

Donna Edwards, programme director for Made Smarter Adoption North West, said: “C-TEC is a fantastic example of how digital transformation, driven by ambition and supported by the right guidance, can unlock productivity, sustainability and future growth. The company’s journey shows that even well-established manufacturers can take bold steps to modernise and future-proof their operations.”

Launched back in 2019, Made Smarter has engaged with thousands of manufacturers, with hundreds receiving support through grant funding, impartial technology advice, leadership and skills training and digital internships to help transform their operations.

*Further information is available online at www.c-tec.com and www.madesmarter.uk