Mowbray Foam Builds Stronger Processes for Future Growth

About Mowbray Foam

Based in Grantham, Mowbray Foam is a specialist foam converter that has been operating for 24 years. The business converts large foam blocks into bespoke shapes for seating, bedding and other furniture, providing businesses across the UK with a quick and highly customised service.

The SME has experienced recent growth, with founder David Freeman bringing his son, Samuel Freeman, into the business to support its continued development, alongside a move to larger premises.

Why did Mowbray Foam seek support from Business Lincolnshire?

Mowbray Foam already had a relationship with Business Lincolnshire, having previously received support to introduce a basic production tracking system. After using the system for around 18 months, and following the move to larger premises, the team wanted to identify further opportunities to improve efficiency and strengthen its processes as the business continued to grow.

In particular, Mowbray Foam wanted to improve how orders moved through the business. Although the team understood its individual processes, it had never formally mapped the full journey from start to finish. This made it more difficult to identify opportunities to improve responsibilities, communication and ways of working.

"We wanted to improve the way orders move through the business but had never formally mapped the process from start to finish. "

Samuel Freeman, Mowbray Foam

How did Business Lincolnshire support the business?

Business Lincolnshire Manufacturing Adviser Trevor Durant worked directly with Mowbray Foam through a series of practical, on-site sessions.

The support began by mapping the business’s order-handling process from start to finish. This helped the team identify five key pain points, including areas of waste, duplication and inefficiency. Between sessions, Mowbray Foam worked on these areas before reviewing progress with Trevor and identifying practical solutions that could be introduced into day-to-day operations.

The support also focused on leader standard work, helping the business establish clearer roles, responsibilities and routines for its management team. These routines were developed around the process map to help ensure essential tasks are completed consistently and progress can be tracked effectively.

"It was a very useful and practical exercise, particularly because the support was based around how our business actually operates. Trevor challenged us constructively, helped us identify issues we had become accustomed to, and gave us practical ideas that we could put into use straight away."

The work has already led to multiple changes within the business.

Mowbray Foam has introduced a new quality control system, a basic but functional production planning system and a hybrid paper and electronic inventory system. The team is also implementing its proposed approach to leader standard work.

"The process has given us a much clearer understanding of where improvements can be made and helped us turn some fairly broad problems into specific actions."

The future

With several improvements already underway, Mowbray Foam now has a clearer understanding of how its operations work and where further efficiencies can be achieved.

The support has also helped team leaders better understand their roles and responsibilities, giving the management team stronger foundations to manage the business as it continues to grow.

For Mowbray Foam, the experience demonstrates how specialist manufacturing support can help businesses take a closer look at established ways of working, identify opportunities for improvement and turn operational challenges into practical actions.

"This is not the first time that Trevor has helped us move our business forward."

If your manufacturing business is looking to improve productivity, streamline processes or tackle operational challenges, Business Lincolnshire’s Manufacturing Adviser can provide practical, tailored support.

Contact Business Lincolnshire to find out how the Manufacturing Academy could support your business.