(12 Oct 2010)
Although the original business, Bison Concrete Products, was a household name in construction circles, its reputation wasn't matched by profitability and in 2008 it went into administration. 

Not long after, a Laing O'Rourke-led consortium assumed management of parts of the business and installed a new leadership team tasked with evolving a trusted brand into an efficient enterprise. Two years later and it seems the hard work has paid off as the Swadlincote hollowcore facility was named ‘Best Process Plant’ at the 2010 Best Factory Awards in September.

This extraordinary turnaround is put down to the introduction of lean manufacturing techniques and Six Sigma training – a management strategy focused on eliminating the causes of defects.

Through a process of restructuring and cost reduction initiatives the entire workforce has helped to find monthly savings worth £383,000 – the equivalent of £4.6 million a year. Productivity and staff engagement levels have also significantly improved.

“The answer was simple”, explains general manager, Stephen Forbes. “Stop spending what you don't need; and when you do need it, buy it cheaper. Engage the shopfloor in the process because they’re the ones who can find the gold nuggets."

Eighteen of the Bison team attended the awards ceremony which was sponsored by Toyota Materials Handling UK.

Laing O’Rourke’s Head of Explore Manufacturing, Peter Varnsverry, said: “This is the icing on the cake in what can only be described as an amazing transformation. I thought we were in with a shout for ‘most improved’, but to see the guys walk away with ‘best process plant’ was completely unexpected.”