Wright Rubber

Laura met Tim Kirby from Made Smarter West Midlands at a networking event, who suggested Wright Rubber would be perfect for the programme.

“As a small manufacturer, we were stuck in our ways to a certain extent but there was so much potential that we could unlock,” Laura said. “We had made a significant investment in the rubber moulding side of the business by buying a larger injection moulding machine, but the gasket side was still very manual for many of its processes.

“We used a ring cutting machine for larger gaskets that were too big to use on the punch presses. This involved setting up the cutter for the size you need and manually turning a handle to cut the gasket. This is a very time-consuming processes and not ideal for large quantity orders.

“If a customer requested a gasket that wasn’t standard, it would require us to purchase a new tool each time. This wasn’t always viable for the customer if it was for a low quantity, so we would either fabricate it by hand or in some cases, lose out to competitors who already had a cutting machine.

“It was very obvious what we needed to do. We needed to digitise the whole process and we knew that a cutting machine was the answer.”

Tim Kirby, Digital Transformation Specialist for Made Smarter West Midlands in Stoke-on-Trent and Staffordshire, added: “The first time I came to visit Wright Rubber, there was a member of staff kneeling on the floor cutting out the rubber by hand. In this day and age, there is so much technology available that can take over this process.

“Wright Rubber needed a digital machine that could carry out cutting, whether large or small, to meet each customer’s requirements.

“We put Laura in touch with WMG at the University of Warwick who came along to carry out a digital roadmap of the business to make sure all their requirements were met.”

Wright Rubber applied for a £20,000 grant from Made Smarter West Midlands, with the business investing an additional £89,711 towards buying a Genesis-V CNC machine from Blackman and White.

Laura explained: “We made the decision to go ahead with the purchase on the same day we found out that we had been successful with the grant. It was like waiting for your results on exams day in the countdown to find out if we would be awarded the funding.

“The support from Made Smarter and WMG from start to finish has been great. Knowing that there are experts to help with any questions you might have and help filling out the forms is invaluable. The team also helped clarify that we were choosing the best machine for our needs and their input was really beneficial.

“It is a 1.6m by 3m machine which allows us to use whole sheets of gasket material without having to cut it down first, and it also has a conveyor system so that we can put a whole roll of rubber on. Once it has cut the first bit, it then clamps down to carry on cutting thereby speeding up the whole process.”

Onur Eren, Principal Engineer at WMG at the University of Warwick, added: “We worked with Wright Rubber to shape a clear digital strategy, focusing on how automation could transform their gasket production and support their long-term growth.

“Our role was to help them shortlist and evaluate different hardware options, ensuring the machine they selected delivered the right balance of automation, accuracy and scalability for their business.

“By taking this structured approach, Wright Rubber has invested in a solution that is already boosting productivity, reducing manual processes and unlocking new opportunities for the future.”

The difference the Genesis-V CNC machine has made is incredible in terms of productivity.

Laura said: “One particular job which previously took two-and-a-half days manually is now completed in 40 minutes! It is mind-blowing.

“The first time we used the machine, we all stood by to watch it in action and we couldn’t believe it had finished. The reduction in labour time is amazing.

“We had an excellent training session on how to use the machine and have subsequently upskilled a member of staff in using CAD packages, which we previously had no experience of in-house. We have a member of staff running the machine full time and we are about to take on another operative, so it’s great to have a growing team.

“We needed to push ourselves to get this project over the line, and we no longer need to sub-contract work that we wouldn’t have previously been able to take on. Not only will this improve our profitability, but it has opened up the door for us to be able to offer a wider range of services. The new machine doesn’t only cut rubber and gasket material, it has the capability to cut cardboard and packaging, textiles, vinyls and sponges and foam – so we can offer a better service to our customers.”

Wright Rubber is planning to recruit two more members of staff – a production operative and a sales assistant – as well as increase its range of services.

Laura said: “As we can now cut different materials, we have already had an enquiry from somebody who makes hip flasks and wanted the leather part cutting that gets wrapped around the flask. It’s an exciting time for both the staff and the company as we embark on the next phase of growing the business.

“I would recommend that other small businesses in a similar situation to us contact Made Smarter. With funding applications, sometimes there can be an overwhelming about of forms to fill out, but I am pleased to say that wasn’t the case here. The process was simple, and the support was there from start to finish.

“I’ve also been on a Leadership for Transformation course which really helped to make me sit down and look at business from a strategic point of view. Usually, you are head down, running the day-to-day business, working hard, but sometimes you need to make the time to sit back - especially with a small team - and think about your growth plans and what direction you need to go in.

“The course helped me with the skills to do that and enabled me to think about what makes Wright Rubber stand out from our competitors and analyse the finer details.

“I would definitely recommend Made Smarter because we are now able to take our business to the next level thanks to their support.”