Insight: Want transformational productivity gains? Align your people, processes and technology

Technology alone won’t deliver the performance boost you’re looking for. That’s the hard truth boardrooms discover after costly digital upgrades fail to move the needle. Sustained productivity comes when your systems, people and processes work in sync. The team at NexSys Solutions shares how to connect the dots and unlock long-term impact.

Every manufacturer wants a factory that delivers more from the same, whether that means higher output, faster decisions, clearer visibility or greater agility in responding to demand. But reaching that level of performance is harder than ever – and even well-intentioned investments can fall flat.

The productivity gap between top and bottom performers remains starkly apparent, with the best companies four to five times more productive than the least – even within the same sector. If more manufacturers matched the output of the top 25%, the UK economy would see an £83bn boost* – enough to lift the UK from 12th to 7th in global manufacturing rankings.

Technology alone won’t deliver that step change but it’s a vital part of the puzzle. The good news is that high-speed, intuitive and automated systems have never been more accessible. The bad news is that companies still struggle to see the returns they expect, despite major investments.

That’s because the real value isn’t unlocked at installation, it’s unlocked when people, processes and technology work in harmony.

At NexSys, a SYSPRO company, we help manufacturers build that alignment from day one. That begins by understanding how your factory actually runs – where time and money are lost, how work flows and where friction lies. From there, we help you implement the right tools and adopt practical steps to deliver measurable progress today and lasting transformation over time.

Start with How Work Really Happens

Digital investments routinely prioritise systems over substance. And yet most bottlenecks aren’t caused by a lack of software; they’re rooted in how work flows (or doesn’t) through the operation.

Manual handovers, undefined processes and disjointed information all create drag. And if those issues are carried over into a digital system, they don’t disappear – they just become harder to fix. The result is frustrated teams, poor adoption and limited gains.

For over 40 years, our innovative ERP+ solutions, consultancy and training have helped manufacturers avoid that trap. Our structured health-check maps cost structures, labour and material planning, communication flows, and process maturity. The goal is to identify the real levers for productivity and prioritise actions that deliver early results.

One of the fastest ways to free up capacity is labour optimisation. Tracking time, exposing bottlenecks and improving schedules can create immediate headroom – often before any new system is fully rolled out. That breathing space gives you and your teams the confidence and capacity to embrace change without feeling overwhelmed.

That’s what is happening at Samuel Heath, a luxury bathroom fittings manufacturer in the Midlands. By introducing real-time data capture, the operations team are gaining clearer visibility into both the amount of and reasons for downtime – two key metrics for controlling costs and boosting output. Backed by solid data, the team are building a case to  report ROI to the board early in the project and secure backing to scale improvements.

The Missing Piece of True Transformation

Technology rarely fails. Change does. Many productivity drives run out of steam not because the tools are wrong but because the transition isn’t managed. We’ve seen time and again that performance gains depend as much on culture and mindset as they do on software and sensors.

Factories live with inefficiencies for years – not because they don’t care but because the current way feels familiar. Changing habits takes courage. Some may turn to high-cost fixes like new machinery, a move that can feel safer to senior leaders than process change. But without clear planning and adoption, even the best kit risks being underused. The same goes for new systems – without early wins and a clear sense of why it matters, engagement fades.

Long-serving employees may be wary of disruption, while newer generations often expect intuitive, digital-first ways of working. That cultural tension must be acknowledged and actively managed.

That’s where structured change management comes in. At NexSys, we guide teams through phased rollouts, tailored training and hands-on support that builds confidence, not confusion.

We help embed change into daily routines, making space for feedback, solving real-world problems and continually adjusting the system to support the work. This builds ownership, avoids resistance, and ensures change is something done with the team – not to them.

Bespoke Challenges to Productivity Success

Ribble Cycles proves what’s possible when people, processes and tech pull in the same direction. As a manufacturer of high-end bikes, the company faced the challenge of scaling without losing its ability to offer highly personalised bikes built to individual specifications.

On the customer side, the online configurator and in-store EPOS system delivered a seamless experience. Behind the scenes, however, disconnected systems meant delays, blind spots and missed opportunities across production and customer service.

Working with NexSys, Ribble brought their retail, production and customer service systems into a single integrated platform – powered by SYSPRO ERP and DataSwitch, our purpose-built integration tool that standardises the flow of information across siloed systems.

Now, when a customer orders in-store or online, the order flows directly into SYSPRO. Procurement, stock control, customisation, final assembly and delivery are all coordinated through the same platform, with automatic updates to keep customers informed throughout.

The results:

• More bikes built than ever, with fewer staff

• Improved stock accuracy and order picking

• Highest product availability in years – with a smaller stock file

• More agile product administration

• Faster and more accurate customer response

Ribble understands that digital transformation isn’t a one-off project, it’s a continuous improvement journey. The company is now looking to streamline stock replenishment, automate communication triggers and tighten carrier integrations. They’ve also established internal champions to drive adoption and keep momentum high.

From Misalignment to Momentum

Too many manufacturers invest in new tech hoping for a performance leap – only to be left underwhelmed. Productivity doesn’t come from buying systems. It comes from aligning people, operations and technology behind a shared goal – and committing to real change.

If your shop floor still runs on paper and tribal knowledge, that’s your sign to start. But don’t go it alone. Nexsys brings decades of experience, structured consultancy and a clear view of what great looks like.

Because when everything pulls in the same direction, productivity isn’t something you chase – it’s what naturally happens next.

Ready to stop firefighting and start scaling? Talk to NexSys and break through to the next stage of growth.