Imagine a manufacturing company shackled by manual processes, struggling to handle just 50 orders a day while errors pile up and growth seems like a distant dream. This was the reality for PROCare, a British manufacturer of accessible bathroom and kitchen solutions, until a transformative solution changed everything. In a competitive market where efficiency can make or break a business, PROCare’s journey from operational chaos to streamlined success offers a compelling story of technology’s power. Dive into how this company scaled nationwide, slashed mistakes, and redefined what’s possible with the right tools.
The Stakes of Staying Stagnant
Efficiency isn’t just a buzzword in today’s manufacturing landscape—it’s the backbone of survival. For companies like PROCare, which started as a modest supplier of shower trays over two decades ago, outdated systems can throttle expansion and frustrate clients. As demand surged from housing associations and contractors across the UK, the company’s reliance on paper-based methods and manual order entry became a glaring liability. The importance of this struggle lies in its universality: countless businesses face similar hurdles, where failing to adapt means risking irrelevance. PROCare’s story is a stark reminder that operational agility is non-negotiable in a fast-evolving industry.
A Turning Point with Technology
Before embracing a game-changing solution, PROCare’s daily grind was a slog of inefficiencies. Warehouse staff often relied on memory to locate items, leading to frequent mistakes and frustrated customers. Processing a mere 50 orders each day was a Herculean task under such constraints. Then came Forterro’s Orderwise, an ERP and WMS solution that shattered these limitations. Suddenly, the company could handle over 200 orders daily—a staggering 300% increase—while managing a much larger inventory with ease. This wasn’t just an upgrade; it was a complete operational overhaul that set a new benchmark for what PROCare could achieve.
Precision That Builds Trust
Errors in picking high-value bathroom components aren’t mere inconveniences—they chip away at customer confidence. In the pre-Orderwise era, PROCare grappled with constant inaccuracies that strained relationships and cost time. The integration of handheld scanners and guided walk routes changed the game, delivering an astonishing 99% picking accuracy. This near-perfect rate didn’t just cut down on returns; it elevated client satisfaction to new heights. Such precision, especially in a complex supply chain, proves that technology can turn operational weaknesses into competitive strengths, rebuilding trust one accurate order at a time.
Scaling Without Breaking a Sweat
Growth often demands more staff and resources, but PROCare defied that expectation. With the new system in place, the company expanded its warehouse to an impressive 75,000 square feet to meet nationwide demand. Remarkably, this scaling happened without a proportional increase in headcount. This efficiency in infrastructure growth highlights how a robust technological foundation can support ambitious expansion while keeping costs manageable. For businesses eyeing similar leaps, this example shows that scaling doesn’t have to mean strain—it can mean smarter operations.
Empowering Customers in a Digital Age
Beyond internal workflows, the transformation extended to how PROCare interacts with its clients. The introduction of a trade portal fueled a surge in online self-service orders, making accessibility a key pillar of the company’s model. Clients now place orders with ease, reducing manual workload for staff and enhancing user experience. This digital shift mirrors a broader trend where empowering customers through technology amplifies a company’s reach and responsiveness. It’s a clear signal that operational efficiency isn’t just inward-facing—it reshapes external relationships too.
Voices from the Trenches
Insights from PROCare’s IT Manager, Adam Balmer, paint a vivid picture of the impact. He describes the system’s adaptability and prompts as “game-changing,” crediting them for enabling growth without resource overload. Balmer is particularly struck by the 99% picking accuracy—a figure so impressive that ISO auditors have questioned its reality. His perspective reveals how technology can instill confidence across every layer of a complex operation, turning skepticism into belief.
Adding to this, Tom Price, Director at Forterro, underscores the strategic value of such a shift. He points out that moving away from outdated systems to a scalable solution gave PROCare the speed and control needed for national expansion. Price’s endorsement highlights a critical truth: technology isn’t merely a tool but a cornerstone for sustained progress in competitive markets. Together, these voices affirm that the transformation went beyond numbers—it rebuilt the very fabric of the business.
Lessons for the Road Ahead
Looking back, PROCare’s journey with Orderwise marked a pivotal chapter in overcoming deep-rooted operational challenges. The leap from 50 to over 200 daily orders, coupled with near-flawless accuracy and expanded infrastructure, showcased what’s possible when technology aligns with vision. For other businesses facing similar roadblocks, the next steps are clear: evaluate current systems for hidden inefficiencies, invest in scalable ERP and WMS solutions, and prioritize digital access for customers. Tracking measurable outcomes, like order capacity or error rates, can guide this evolution. Ultimately, PROCare’s experience serves as a blueprint, urging companies to embrace innovation not as an option, but as a necessity for thriving in a relentless industry.
