Roger Hartshorn, CEO of Sheerlie, explains how strategic stock management has improved cash flow for Lister Window Systems.

Positive cash flow is critical in manufacturing. Too often, businesses in our sector chase high sales volumes, only to struggle with delayed customer payments and cash shortages.

Stockpiling inventory also ties up vital cash, which is especially risky amid supply chain uncertainty. Volume discounts from overseas aluminium suppliers can also tempt fabricators to over-order, increasing both costs and risk.

But the aluminium supply chain doesn’t have to work this way, and fabricators shouldn’t bear all the risks. I wanted to share a success story of how the aluminium sector is changing.

I recently spoke with Steve Gardiner, Group MD at Lister Window Systems. One of the UK’s largest trade window and door fabricators, Listers operates from Essex and Stoke-On-Trent and has built a strong reputation for innovation, sustainability, and operational resilience.

A long-term fabricator of PVC-U and aluminium products, Listers became an early Sheerline Aluminium customer in 2020.

Releasing cash

During our conversation, Steve highlighted the benefits of switching to Sheerline. The big one that stood out to me is that Listers’ Essex site has been able to release almost £100,000 of cash previously tied up in stock!

This has been thanks to the delivery speed, quality and reliability they receive from Sheerline, along with a new software system.

In fact, their finance director initially thought the stock had gone missing due to how smoothly the transition happened!

How they did it

Many fabricators find it necessary to overstock aluminium profiles because of slow and unreliable lead times. Listers previously had to order 6-8 weeks in advance and couldn’t depend on complete deliveries. That uncertainty meant holding extra stock to avoid production delays and the risk of damage.

They also had to store a wide range of product-specific components and maintain surplus due to aluminium’s storage and handling costs – both much higher than with PVC-U products.

With Sheerline, all that has changed. Steve explained: “With Sheerline’s five-day lead times, our processes have become much more efficient. This has significantly reduced both waste and energy use, aligning with our sustainability goals.

“Accurate delivery reports notify us of any missing items in advance, allowing flexible scheduling. Overall, Sheerline’s shorter lead times have helped us improve customer service and reduce idle time and waste.”

Quality control

“Sheerline’s British-based extrusion and powder coating operations ensure consistent quality – the profiles have no overseas transit and minimal handling,” continued Steve. “Damage is rare, but if it does happen, replacements arrive in just three to five days. This lowers remakes and waste, supporting our sustainability goals.”

Product design

“Sheerline’s design team welcomes feedback,” said Steve. “Their system uses minimal components across the range – like the universal Fast Connect Hybrid Bead, which simplifies stockholding and has been a hit with fitters for ease of installation.

“We also enjoy the ability to offer award-winning ‘industry-first’ innovative products to our customers.”

Reliable deliveries

“Our fabrication operation can now work on an almost perfect ‘Just In Time’ basis,” Steve added. “We know that everything listed on the Sheerline delivery report will turn up, reducing our reliance on stock and freeing up space and cash.”

Listers invested in software to identify excess stock at Essex and reduced their inventory in line with their faster deliveries. The released cash is now reinvested in the business, with plans to replicate the process in their Stoke facility soon.

“Demand for aluminium products continues to rise across the industry. The freed-up cash from stock has enabled Listers to invest in energy-efficient machinery, boosting operational performance and environmental outcomes – a true win-win!” concluded Steve.

It’s rewarding to see Sheerline’s service investments having such a measurable impact on our customers. We built our business to support fabricators like Listers and also their installer customers, and it’s great to see those decisions paying off.

Thanks to Steve for sharing this story – hopefully it inspires others in our industry.

If you manufacture aluminium windows, doors, or roofs and want to see how Sheerline could benefit your operations, get in touch with me or one of the sales team!