Century Composites Ltd

Their leading-edge carbon fibre components go into fishing rods, industrial, automotive and aerospace products, all of which are sold globally.

The entire workforce is committed to uncompromising quality both in the design and production processes and in the final component parts they deliver, customers expect zero defect quality from their carbon fibre components. Lives as well as performance are at stake.

In fact, one of their clients – the Jordan Grand Prix team – has rated Century’s supplier performance as ‘A’ class.

The challenge
Put simply, the challenge in manufacturing today is to be better, faster and cheaper.

Consequently, many SMEs have gone east in search of cheap components. But Century Composites Ltd resolved to strengthen their leading-edge reputation for innovation by continuing to make all their component parts in the UK.

“We were looking for more efficient ways to run the business to stay in the West and not have to go to the East to buy in parts,” says co-director Vicky Chilcott.

The solution? Create an atmosphere of continuous improvement and a highly flexible workforce of individuals who can multi-task, thus enabling the company to move people around as required and increasing efficiencies throughout the business.

To this end the directors set four goals:

1. Share and centralise information about all procedures.
2. Create a skilled, flexible workforce.
3. Manufacture in the most innovative, fastest, cheapest way possible.
4. Improve customer satisfaction.

First steps to meet the goals
The company recognised that by taking steps towards full certification for an Integrated Management System (IMS) they would achieve their goals.

An IMS is a management system integrating all components of a business into one coherent system.

The management system has to include every company activity influencing final business results. That’s why a full IMS often focuses on quality, health and safety and environment.

All the processes and the documents that describe them are integrated in the IMS.

Cross-linked procedures
Century Composites Ltd realised that their procedures rarely occurred in isolation. In fact, many were cross-linked.

A good example of this is a health and safety programme for dust control. First there is the issue of breathing in dust (health and safety); second, the issue of preventing dust getting into uncured carbon fibre during manufacturing (quality issue); third, the issue of preventing dust getting into the environment (environmental issue).

This meant seeking certification in three standards:

• ISO 9001 – Improves a company’s product and service quality; gives customers confidence that their needs will be met; standardises a company’s business by giving it a consistent approach to its operations; improves work processes, efficiencies, staff morale, and reduces waste.
• ISO 14001 – Contains management principles to help reduce the risk to the environment of a company’s operations and products. Conservation and care of the environment are critical.
• OHSAS 18001 – The people who create a company’s products need to be certain that they work in a safe factory where risk is managed and their health is of paramount concern.

SGS United Kingdom Ltd’s early role in the certification process
Century Composites Ltd talked to three leading certification organisations early in 2001 and received quotes from each one.

“There was simply no point in going for the one standard only. SGS United Kingdom Ltd came back offering the best way for achieving the three standards at once. The others couldn’t do all three together,” says Vicky Chilcott.

Following SGS United Kingdom Ltd’s advice the company started to plan for certification. First they brought in a consultant.

Between July 2001 and July 2002 the consultant showed them what steps they had to take to meet the standards. Together they developed quality, environmental and health & safety systems that set objectives; then measured, monitored, analysed and planned for continual improvement across every aspect of company activity.

The consultant spent time with the staff, watched what they did, and documented procedures. This formed the basis of their working standards.

The audit process
In May 2002 SGS United Kingdom Ltd came in to carry out a pre-audit over a two-day period. They compared what the company were saying they did with what the standards required and what they were actually doing. After this pre-audit, Century Composites Ltd polished up their documentation and procedures.

Then in July 2002 SGS United Kingdom Ltd returned to carry out a full audit.

The audit involved numerous face-to-face interviews and a close examination of operations, processes and plans. Yet despite all this work, the audit caused minimal disruption to the company’s everyday business.

Working with SGS United Kingdom Ltd
“SGS United Kingdom Ltd communicated with us throughout the process. They explained everything in clear English and advised us throughout,” says Vicky Chilcott.

The audit proved a success and Century Composites Ltd became one of the first companies in the UK to be accredited to ISO 9001 (Quality), ISO 14001 (Environment) and OHSAS 18001 (Health and Safety).

What’s more, the relationship with SGS United Kingdom Ltd did not end after certification.

SGS United Kingdom Ltd continues to inform the company about any changes in legislation and standards likely to affect their business.

The company rely on their practical suggestions, many of which have since become new working practices.

For example, when a waste collector calls their credentials need checking. Now everyone in the firm knows how to check their certification with the Environment Agency.

What benefits does certification deliver today?
Century Composites Ltd is a rare firm to be still manufacturing in the West. Their competitors have gone to the Far East.

The business is in better shape than before certification. The consultant told Century Composites Ltd that a successful IMS delegates all responsibilities throughout the company so you get a buy-in from everyone in the company.

Now information is devolved down through the company. If there’s a complaint from a customer, everyone knows how to handle it. If there’s uncertainty around document management, there are clear guidelines everyone understands.

“Certification has given us both qualitative and quantitative benefits,” says Vicky Chilcott. “Our staff is proud to have the standards. As a consequence of certification, we have a very strong bottom line, good profits, and good growth.”