In the demanding world of motorsport, automotive, and marine industries, precision, traceability, and efficiency are paramount. Horizon Wiring Limited, based in Norfolk, UK, has rapidly established itself as a leading manufacturer of bespoke wiring looms and harnesses by embedding these principles into the very fabric of its operations from day one. This case study explores how Horizon Wiring, in just two short years, leveraged Flowlens as its foundational enterprise resource planning (ERP) system to achieve remarkable growth, maintain stringent quality standards, and redefine industry best practices.
A Vision for Modern Manufacturing
Founded two years ago by MD Sean Taylor, and business partner Ben Buckmaster, Horizon Wiring set out with a clear vision: to escape the traditional, often chaotic, paper-driven processes that plagued the wiring and harnessing industry. With over 25 years of experience, Sean understood the inefficiencies inherent in manual systems – a lack of traceability, fragmented serial number / asset management, and inaccurate stock control.
“I’ve worked in this industry for over twenty five years, and we never had a system where we were able to trace parts, you know, assets and what we actually create,” explains Sean. “Having a system that allowed us to kind of bring all these things together in one was really important from a financial and also, from an efficiency point of view.”
This commitment to a digital-first approach led Horizon Wiring to seek an integrated software solution from its inception. The goal was to build a business that was not only productive but also highly responsive, accurate, and scalable.
Why Flowlens? Maximising Value and Potential
When evaluating potential MRP systems, Horizon Wiring conducted a thorough market review. Their criteria extended beyond mere functionality; they sought a solution that offered comprehensive utility without unnecessary bloat.
“What Flowlens offered was, from our point of view, was maximum use of the software,” Sean states. “We are currently using probably 90 to 95% of what’s available on Flowlens, which is something that other things we could have used 50%, but the rest, we’re paying for something we’re not actually using. So it was quite important for us to get maximum for our money, basically.”
This high utilisation rate speaks volumes about Flowlens’s suitability for Horizon Wiring’s specific needs, ensuring that their investment translated directly into operational advantages.
Sean Taylor: Strategic Growth and Tangible Savings
As Managing Director, Sean Taylor emphasises how Flowlens has been instrumental in Horizon Wiring’s rapid ascent. The company has grown from just three individuals at its founding to a robust team of 35 employees in two years – a tenfold increase in headcount that is still growing. Yet, this explosive growth hasn’t necessitated a proportional increase in administrative overhead.
Unprecedented Efficiency and Responsiveness
One of the most immediate benefits realised through Flowlens is the speed and fluidity of Horizon Wiring’s operations:
- Rapid Quoting: “The quoting process for us is very quick because our system just we just bang, bang, bang, upload, and it just happens very quickly… We’ll get a drawing one day and literally within space of two to three hours, they receive the quote.” This rapid turnaround fosters strong customer relationships and accelerates project initiation.
- Streamlined Internal Workflows: Beyond quoting, Flowlens facilitates seamless communication and task management within the workshop. “Everything’s on Flowlens via tasks, via messages. So everything’s just streamlined to be as efficient as possible all the way to dispatch.” This eliminates unnecessary movement and discussions, keeping technicians focused on their work.
- Flawless Stock Management: Critical for a manufacturing business, Flowlens provides a highly accurate stock and serial number management system. “Having a limited stock but being able to react quickly if we if we see the stock is running low and replenish quickly, but having that on a software which allows us to track it was very important to us.” This prevents overstocking and ensures parts are available when needed.
A Lean Administrative Footprint
Perhaps the most compelling financial benefit is Flowlens’s enablement of a remarkably slim administrative team. Despite the 10x growth in workforce, the company manages with essentially two administrative personnel.
“Our admin team is very slim, but the reason it is very slim is because they’ve got software that’s so easy to use and that does so much for them and so quickly,” Sean explains. “Having that software that’s allowed us to manage a business with 35 people in it with two people essentially is incredible. And that has got to be a saving point financially because it means we don’t have to employ so many people.”
Environmental Stewardship
Sean is passionate about reducing the environmental impact of his industry. Flowlens has played a crucial role in achieving a largely paperless operation:
- Eliminating Paper: “The industry traditionally was very paper driven. So a lot of printing of drawings, a lot of printing of job cards… which with this system has completely eliminated that. We’re fully electronic.”
- Reduced Waste: This not only streamlines processes but also aligns with the company’s environmental goals, significantly cutting down on paper consumption.
Unparalleled Traceability – A Competitive Edge
An initially unexpected, but profoundly valuable, benefit of Flowlens has been the unparalleled traceability it offers. This is particularly crucial for higher-end customers and in the marine sector, where products often return for servicing.
“The serial numbers, for example, and that offering that traceability to customers from beginning to end on a build. Even if it comes back for a service, we can use that asset number to re-enter the part back into our hands as opposed to showing it’s been dispatched,” Sean reveals. “There’s a full traceability, which I must admit, I didn’t expect when we first started… offering customers that amount of traceability is something that I don’t think the majority of our competitors can offer.”
In essence, Flowlens has become the central nervous system of Horizon Wiring. Sean’s sentiment is clear: “I’d be lost. The entire business is based around the use of Flowlens and the benefits that it brings us. And, if we were to have that removed from us, we’d be in a bit of a pickle, I must say.”
Isaac Jones: Quality Control and Operational Excellence Redefined
Isaac Jones, Quality Lead at Horizon Wiring, is at the forefront of ensuring every product meets the exacting standards of their industries. For Isaac, Flowlens is not just a tool; it’s the backbone of their quality management system, providing robust control, meticulous tracking, and critical support for compliance.
Seamless Quality Processes
Isaac primarily utilises Flowlens for all quality control and tracking, overseeing the entire lifecycle from initial quoting to final dispatch.
- Integrated Forms: “When a technician is building something for us, they’ll fill out one of the Flowlens shop floor quality forms to accompany that individual item.” These forms are then sent to the quality department, where Isaac’s team conducts checks and completes detailed quality control forms, essential for ISO accreditations and customer compliance.
- Linked Documentation: Non-conformance and concession forms are easily accessible and linked to the individual asset, ensuring a complete record accompanies each item through its journey to dispatch.
- Paperless Operations: A significant shift from previous roles that relied heavily on physical paper forms. “We have almost a completely paperless way of working and Flowlens really helps us rather than something getting a quality control form that’s paper and has been hand signed and ticked, and you lose that and you lose that traceability. Whereas for us, everything’s just there.”
From Manual Chaos to Streamlined Clarity
Isaac vividly contrasts Flowlens with the manual systems of his past:
- Eliminating Manual Cross-Referencing: “In previous roles those quality forms and checks would be done, but they’d be on a either on a piece of paper… or with the spreadsheets, you sort of have to cross reference all of your relevant spreadsheets to get something right.”
- Automated Information Flow: “Flowlens, without really needing to think about it, it carries itself through with how you set up the forms. You can add assets. You can add job cards, individuals’ names, companies, and things like that. It just makes it a lot easier to get all the information you need and none of the information you don’t need on a certain form.”
- Reduced Resource Needs: The system’s automation has freed up valuable resources. “Previously, there would have been someone who’d have to have stayed on top of all of our spreadsheets and making sure they’re right every week… And Flowlens does that for us, so it eliminates the need for that person.”
ISO Accreditation Made Easier
Horizon Wiring recently achieved its first ISO 9001 and 14001 accreditations, a process significantly simplified by Flowlens.
- Pre-built Foundations: “Flowlens has meant that that almost 60% of my work had been done, and it was just about working with our health and safety person in charge of our ISO accreditation for us and writing the procedures that tie in to what we already do with Flowlens.”
- Simplified Audits: During audits, Flowlens provided a seamless experience. Auditors could easily view system overviews and generate comprehensive PDFs of project paper trails. “It was really simple… there was just an individual paper trail for what we needed to do, which made it a lot easier and clearer if they had any questions because everything is always identical by the information of a given customer.”
Invaluable Asset and Serial Number Tracking
The ability to track individual assets via customer-dictated serial numbers has proven profoundly beneficial:
- Customer-Specific Traceability: “Because Flowlens allows us to put in whatever serial number we want for a given job card and a build, we just simply input their serial number. So their serial number becomes our serial number.”
- Comprehensive Service History: This enables Horizon Wiring to quickly find full information on any assembly, including modifications, repairs, or issues, especially crucial for marine clients whose products return for servicing.
- Tracking Internal Assets: An unexpected benefit has been the ability to track internal testing equipment as assets within Flowlens. This means Horizon Wiring now has visibility into the cost and time investment in their test leads and equipment, which was previously unknown.
For Isaac, Flowlens is defined by two key attributes: “If it was in two words, it would be streamlined and traceable. That’s for me for my for my work and my my role, that’s they’re the two things that I find most useful.” He estimates Flowlens saves him “tens of hours a week” by providing instant access to filtered data for monthly reviews and reporting.
Victoria Owen: The Backbone of Daily Operations
Victoria Owen, Horizon Wiring’s Office Administrator, is the frontline user of Flowlens, handling all purchasing, invoicing, and dispatches. Her perspective highlights the system’s ease of use and its central role in streamlining the company’s daily financial and logistical operations.
Everything in One Place
Victoria’s most significant appreciation for Flowlens stems from its integrated nature:
- Centralised Operations: “The biggest benefit for Flowlens is everything is all in one place from start to finish, from when we send out quotes to invoicing at end.”
- Sequential Workflow: The system guides her through a logical progression: accepted quote → sales order → visible parts → creation of purchase orders →shop floor jobs and data capture → quality inspection → dispatch → invoicing. “It’s all in stages, and it’s really, really easy.”
Bypassing Fragmented Systems
In previous roles, Victoria grappled with disparate systems for different functions. Flowlens has eliminated this inefficiency.
- No More Application Switching: “In previous roles, I was using, like, spreadsheets… I had a different application for, like, invoicing and then orders. So it wasn’t all in one area. So it was just more time consuming.”
- Self-Sufficient Platform: With Flowlens, she can manage nearly all her tasks. “All I need is Flowlens, really. So that’s good.” The ability to add files and uploads to any record further enhances its utility.
Streamlined Purchasing and Goods In
Given Horizon Wiring’s high volume of daily deliveries and ongoing projects, Flowlens is critical for efficient purchasing and stock management.
- Daily Purchasing: Victoria makes purchases every day, uploading numerous purchase orders. The system clearly lists outstanding builds and what needs to be ordered.
- Efficient Deliveries: “Flowlens is easy because it’s all listed, and I can see what is outstanding… I just go on Flowlens, look at the purchase orders, see which company comes from what, and then I know what job it’s for, really.”
- Automated Stock Updates: Upon delivery, Victoria processes goods-in notes, which automatically update stock levels in Flowlens, ensuring inventory accuracy.
Seamless Xero Integration
The integration with Xero, Horizon Wiring’s accounting software, is a vital feature, especially with a remotely working business partner.
- Automated Payments and Invoicing: “Once I check the goods in, I send that purchase order to Xero. So in thirty days, that’ll automatically tell that we need to pay them.” Similarly, invoices generated upon dispatch are sent to Xero to track receivables.
- Full Financial Traceability: This ensures complete visibility and accurate financial records, essential for the remote team.
User-Friendly Design and Responsive Support
Victoria praises Flowlens’s intuitive design and the responsive support provided by the Flowlens team.
- Simplicity and Clarity: “It’s just really simple. Like, it’s laid out simple, and I really like that. Like, it’s just easy to use… it’s got everything on it that we need.”
- Reliable Customer Care: For any queries, Victoria emails customer care and works with the Flowlens team, who organises Zoom chats and resolves issues quickly. “We need quick responses and that’s what we got.”
Victoria estimates that Flowlens “saves me hours a week, absolutely hours because I don’t have to switch between applications. It’s just all in one place and all the information I needed were in front of me.” Her ultimate summary of Flowlens: “Really, really organised and it’s just so easy. It’s really straightforward, so easy to use, not complicated, but it’s got everything on it that we need.”
Conclusion: A Partnership for the Future
Horizon Wiring Limited stands as a testament to the power of thoughtful system implementation. By choosing Flowlens as their core operational platform from the outset, Sean, Isaac, Victoria, and the entire team have built a business capable of rapid growth without compromising on efficiency, quality, or environmental responsibility.
Flowlens has enabled Horizon Wiring to:
- Scale Rapidly: Accommodate tenfold employee growth with minimal administrative overhead, delivering significant financial savings.
- Achieve Operational Excellence: Streamline quoting, production, and dispatch processes, leading to faster turnaround times and increased customer satisfaction.
- Guarantee Unrivalled Traceability: Offer customers comprehensive product history and service tracking, a key differentiator in a competitive market.
- Maintain Peak Quality Standards: Simplify quality control, automate record-keeping, and significantly ease ISO accreditation processes.
- Embrace Paperless Efficiency: Drastically reduce paper consumption, aligning with modern environmental practices.
- Foster a Connected Workforce: Provide a single source of truth for all business data, accessible to all relevant team members.
Horizon Wiring’s success story is a clear demonstration that with the right technology partner, even a nascent business can set a new standard for efficiency and excellence, ensuring a solid foundation for continued innovation and leadership in its specialised industries.
As Sean Taylor aptly summarises the impact of Flowlens on Horizon Wiring:
“I’d be lost. The entire business is based around the use of Flowlens and the benefits that it brings us. And, if we were to have that removed from us, we’d be in a bit of a pickle, I must say.”
