O.I.C. Valve Covers Ltd is a family-run manufacturer based in Oxfordshire, specialising in the design and manufacture of bespoke thermal insulation jackets, metal cladding and generator insulation systems. Serving customers across industrial, energy and data centre sectors, the company has built a strong reputation for quality, flexibility and customer service through its highly skilled workforce and commitment to continuous improvement.
A key bottleneck within the business was the manual marking out and cutting of insulation fabrics using paper templates. This process relied heavily on operator skill and experience, requiring approximately 24 hours of labour each week while creating variability in accuracy and material utilisation.
The manual process also limited production capacity, making it difficult for the company to respond quickly to larger customer projects. Material waste was estimated at around 15%, while quoting and production planning depended on historical knowledge rather than reliable production data.
As demand increased, O.I.C. needed a solution that would improve productivity, reduce waste and create the digital foundations required to support future growth.
Following participation in the Made Smarter South East programme, O.I.C. identified the implementation of a CNC automated fabric cutting machine with integrated CAD/CAM marker layout software as a key investment to support its digital transformation.
The new system enables patterns to be created, stored and reused digitally, replacing paper templates and manual cutting processes with an automated and highly accurate workflow.
The project includes:
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CNC automated fabric cutting technology.
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Digital pattern creation and storage.
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Marker layout optimisation software.
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Staff training in CAD/CAM design and CNC operation.
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Integration of digital workflows into production processes.
The investment has fundamentally changed how O.I.C. approaches production.
By automating the cutting process, the company has removed a significant production bottleneck and introduced greater consistency, repeatability and traceability across manufacturing operations.
The CNC cutting machine increases cutting capacity from approximately 60 mats per day to more than 200 mats per day when required, providing the flexibility to respond to larger orders and tighter customer deadlines.
At the same time, manual cutting labour has been reduced from around 24 hours per week to fewer than five hours, allowing experienced employees to focus on higher-value production activities.
"O.I.C. Valve Covers represents exactly the type of ambitious SME that can benefit from digital adoption. By replacing labour-intensive manual processes with CNC cutting technology and digital workflows, the business is increasing productivity, reducing waste and creating the capacity needed to take advantage of new market opportunities. The project demonstrates how targeted technology investment can deliver immediate operational benefits while laying the foundations for long-term growth and resilience."
Jez Heys, Technology Adoption Specialist, Made Smarter South East
The project is expected to deliver significant operational and financial benefits, including:
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Annual labour savings of approximately £16,200.
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Material waste reduction from 15% to 7%.
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Annual material savings of approximately £3,300.
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Total annual efficiency savings of approximately £19,500.
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A forecast payback period of around two years.
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Increased production capacity of more than 230%.
These benefits are expected to support improved profitability and operational resilience while creating capacity for future growth.
The project is not only transforming production processes but also investing in people.
As part of the implementation, multiple employees are being trained in digital pattern design, CAD/CAM software, CNC programming and machine operation. This helps to embed digital skills within the business, reducing reliance on individual knowledge and supporting succession planning for the future.
The involvement of the next generation of leadership is also helping drive the company's digital transformation agenda and ensure technology adoption remains central to long-term growth plans.
The introduction of automated cutting technology is expected to have a positive environmental impact by reducing material waste and improving resource utilisation.
By improving pattern optimisation and cutting accuracy, the company expects to save around 800 mats' worth of material annually. Digital pattern storage and workflow management will also reduce paper consumption and support more efficient production planning.
With the support of Made Smarter South East, O.I.C. Valve Covers is building a more efficient, scalable and digitally enabled manufacturing operation, able to fulfil growing demand and ambitions to expand into new markets.
Jack Davies, Project Manager at O.I.C. Valve Covers said: "Working with Made Smarter has enabled us to consider and invest in technology in the right areas for our business. The new cutting machine will improve efficiency, increase productivity, enable us to fulfil larger orders, and support our growth into new markets, including the marine sector."
The new technology creates a platform for future growth, allowing the company to pursue opportunities in new markets such as marine insulation, technical textiles and wider industrial applications.
Improved productivity, enhanced digital capability and increased production capacity will help strengthen competitiveness while supporting sustainable long-term growth.
The business is now considering enrolling some key staff in the Digital Champions course to actively continue on its digital change journey.
