Made Smarter helps fire safety manufacturer streamline and scale with warehouse upgrade
A leading UK manufacturer of fire alarm and life safety systems is unlocking growth through digital adoption, supported by Made Smarter.
C-TEC, based in Wigan, 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.
With support from Made Smarter, the government-backed technology and skills adoption programme supporting SME manufacturers, C-TEC, has increased productivity by 25%, eliminated dispatch errors and cut out paper waste, supporting C-TEC’s sustainability goals.
The project, supported by a £20,000 grant from Made Smarter, has also laid the foundation for scaling operations, introducing new, disruptive fire safety products, and creating four new jobs.
Peter Butterworth, Manufacturing Operations Director at C-TEC, said: “Made Smarter didn’t just help us identify a problem, they gave us the confidence and support to act on it. Their backing enabled us to accelerate our digital transformation, eliminate inefficiencies, and build a smarter, more scalable operation ready for the future. It’s been a genuine turning point for our business.”
C-TEC started 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 £25m manufacturer of world-class life safety systems, exporting to over 80 countries.
From its 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. Meanwhile, just a few miles up the road in Mawdesley, the company has a dedicated R&D centre of 25 engineers driving product innovation.
The Grenfell tragedy was a turning point for the industry, prompting C-TEC to accelerate development of smarter, connected systems with enhanced monitoring and evacuation capabilities. This innovation has opened doors to major projects in high-rises, stadia, hotels, hospitals, and shopping centres.
Despite sustained growth through investment in systems, people, and processes, C-TEC recognised that its warehouse capabilities needed modernising.
A digital transformation workshop delivered through the Made Smarter programme revealed key challenges: high product variety and volume, reliance on manual stock handling, and paper-based inventory control processes were contributing to errors, inefficiencies, and bottlenecks.
“We’ve got around 9,000 part numbers across finished goods, sub-assemblies, and raw materials,” said Peter. “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.”
To tackle the challenge, C-TEC implemented IFS’s 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 annually, advancing its net zero goals and ESG credentials.
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, it’s about culture,” said Peter. “Our people are now more confident, faster, and equipped with real-time data.”
WaDaCo is futureproofed 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.
Commenting on the success, Donna Edwards, Programme Director, 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. Their journey shows that even well-established manufacturers can take bold steps to modernise and futureproof their operations.”
Launched 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 businesses.
To learn more visit: madesmarter.uk
About the Author
Dave Staddon - Publisher
Co-Founder of MDM Publishing Ltd. He has worked in fire publishing for close to 30 years. The company's portfolio includes International Fire Protection, International Fire Fighter, Asia Pacific Fire, Gulf Fire & UK Fire.
