Endurance ® Doors has unveiled a new investment with the ability to deliver transformative
benefits for its business.
The manufacturer of high-end composite doors for quality-minded installers and homeowners
officially opened a remodelled and significantly upgraded assembly hall at its Brigg
production site on Wednesday 17 th September 2025.
To mark the occasion, a commemorative ribbon was cut by Stephen Nadin, CEO of the
Endurance group, and Dawn Huntrod, Regional Director (North) from Made UK – the not-for-
profit organisation which champions UK manufacturing and engineering.
Commenting, Tom Stephens, operations manager at the Endurance group, said “The launch
of our new assembly hall marks a significant milestone in Endurance’s relentless pursuit of
production excellence.
“It has been developed following an investment of over £200,000 and as part of our ongoing
journey towards truly lean manufacturing, where our entire operation is geared around
minimising waste, maximising productivity and delivering the greatest value for our
customers.”
Drawing on inspiration and experience from the automotive industry where lean
manufacturing is the sector norm, Endurance’s new assembly hall employs a single piece
flow system as opposed to the more commonplace batch production method.
This innovative approach optimises production speed and volumes whilst simultaneously
ensuring better quality control.
New Endurance doors now pass along a line of carefully planned workstations with
conveyors, tilting tables and other specialist technology being employed to reduce physical
handling.
This reduced handling minimises the risk of damage to the door and the amount of exertion
required by production operatives, enhancing their welfare and protecting them from potential
injuries.
Each workstation is also dedicated to a specific part of the door production process and sees
operatives working to a well thought out and thoroughly defined set of standard operating
procedures. This helps to ensure consistently high standards of quality and workmanship as
well as minimal scope for human error.
Production accuracy and efficiency are further enhanced by a new MES (Manufacturing
Execution System). Making full use of digitalisation, this system uses barcoding to allocate
the correct components to a specific door. It also provides operatives with easy to follow
guidance, including instruction videos, on best practice component fitting.
In addition, a new and dedicated packing cell has been developed. This supplies both the
workstations in the assembly hall with components and collates and packs ancillaries, such
as handles, cylinders and escutcheons, which are supplied separately with the door for fitting
by the installer.
This packing cell uses QR code scanning to identify what items are needed on each order
and to ensure the correct parts are picked and packed with exceptional accuracy and
reliability.
Tom concludes: “There are four core principles to lean manufacturing, which range from
striving for continuous improvement through to understanding the customer and their
perception of value. These maxims are becoming increasingly embedded within the fabric of
Endurance ® Doors and the wider Endurance group.
“As a business we have already accomplished much and adopting lean manufacturing will
help us to take those achievements to new levels.
“Our new assembly line will be a catalyst in that. It will enable us to offer doors on shorter
lead times and with even greater quality assurances, meaning fewer issues and potential
callbacks for our installer partners as well as increased homeowner satisfaction.
“We are understandably proud of the investment into our new assembly hall.
“So much so in fact, that we welcome customers to visit us and to experience the many
benefits it can offer for themselves.”
