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Birmingham’s Instinct Hardware has accelerated its production push, lifting manufacturing capacity by 15% after a tech-led overhaul shaped by insights from the Help to Grow: Management Course. Founded in 1989, Instinct Hardware now employs about 50 people across digital, operations and manufacturing teams. Where previous growth came from extra headcount and factory space, the new playbook prioritises productivity and smarter processes. The change in pace is being piloted by director Nil Chohan, who spent four years on the shop floor before stepping up to take over from his father, co-founder Ray Chohan. To drive this change, Nil enrolled on the 12-week Help to Grow: Management Course, which is available at Small Business Charter accredited business schools across the West Midlands What actually changed inside the factory Multiple upgrades are reshaping day-to-day manufacturing: Digital tooling: Wider adoption of computer-aided design, rendering software and material requirements planning is tightening specifications, reducing rework and aligning inventory with real demand. Workflow redesign: Cross-department bottlenecks are being mapped and removed, allowing faster handoffs between engineering, coating and dispatch. New in-house capability: A purpose-built powder-coating facility brings previously outsourced work under one roof, giving tighter control of finish quality and lead times. Customer transparency: A manufacturing execution system now provides clearer order status updates, helping customers plan installations with confidence and strengthening trust in the brand. Together, these moves underpin the 15% capacity uplift, giving the business more headroom in peak periods and a sturdier platform for growth. For customers, the gains show up as more reliable lead times, better product availability and real-time visibility of orders. For the team, the shift reinforces a culture of continuous improvement, with clearer data, fewer stoppages and a stronger link between design intent and final finish. Why Help to Grow: Management mattered The 90% government-funded, 12-week Help to Grow: Management Course is delivered by accredited UK business schools to help leaders sharpen strategy, leadership and operations. Nil credits the course’s practical frameworks, peer networking and one-to-one mentoring with clarifying priorities and accelerating change. “Digital transformation is something that should excite us all in the sector; it’s a huge opportunity to create a more refined service offering and make sure we’re continually developing the customer’s experience,” he said. Nil added that the course made operational goals “clearer than ever,” helping him pinpoint where to streamline processes and add value through digital adoption. Next on the roadmap The business says a Knowledge Transfer Partnership with Aston University and Innovate UK is bringing real-time data systems onto the factory floor, with two academics working alongside in-house specialists to improve decision-making and throughput. With around 50 specialists already in place, the company intends to push efficiency further without immediately adding headcount or expanding its footprint. The wider SME picture Instinct Hardware’s experience reflects a broader trend among UK manufacturers adopting targeted digital tools over large capital expansions. According to the programme, more than 10,000 leaders have completed Help to Grow: Management, and 93% of alumni surveyed would recommend it - an indicator that structured learning, mentoring and peer support can translate into practical, measurable gains. For this Birmingham manufacturer, growth is being built not by getting bigger, but by getting sharper - turning data, design and discipline into a competitive edge customers can feel. To find out more about the Help to Grow: Management Course, click here.
