Liverpool processor is well placed to benefit from olympics hansen changes up a gear

HansenGlass enjoys a rarified position among glass processors as one of the few UK companies dedicated to servicing large commercial glazing orders. Through glazing contractors, including its sister companies, a huge number of key projects have been undertaken. The Liverpool processor is supplying the new Wembley stadium, projects for Liverpool’s Capital of Culture, and is well placed to benefit from the 2012 Olympics in due course.

This year has seen a few changes at management level as senior figures have moved on. Mark Towers is the new Managing Director, and he joins the business from a manufacturing background, supplying to the building industry. Mark replaces Martin Walsh, who is taking a well-earned sabbatical after being with Hansen since 1997. Richard Kells provides technical support alongside John Colvin. Kristian Kolby joins in a Sales & Marketing role.

‘What Martin has created is a stronger foundation for our business’, says Mark Towers, paying tribute to his predecessor. ‘He specifically looked at the markets and sectors that we wanted to sell into – structural glazing and thick glasses to complement the large IGU contracts sourced from leading curtain walling companies.’

Substantial investment

Recent substantial investment at HansenGlass’s facility in Kirkby means that these markets can be serviced more effectively and efficiently. Around £5 million has been spent on plant and machinery, and a new office area. Under the guidance of Operations Director Ian Whalley, the factory has been planned to service three main value streams: thick glasses, structural glazing and large IG units. Because of the weight of the pieces, very little manual handling is involved. A Bystronic cutting and breakout table sends pieces through twin edging machines with online drilling, arranged in a horseshoe configuration. Other machinery includes a Tamglass ProE furnace with 25mm glass thickness capability, two heat soak ovens and a Lisec IG line, Intermac CNC centres and a Thieme screenprinting line which is the largest in the UK, says the company.

IG units typically use aluminium spacer, a butyl primary seal and a silicone secondary seal comes as standard. Bar coding instructs the various processes providing traceability of all orders.

ThermoSpan

It’s a description the management shy away from, but Hansen Glass is a one stop shop for curtain walling. ‘Curtain wallers, typically working on contracts of over £1 million, can come to us and get everything they need.’ says Kristian Kolby.

ThermoSpan is the HansenGroup’s own glazing system which is available as single, double and triple skin and laminated. Laminated and double skin IG units are fixed only through the inner pane to achieve a flush exterior – making a great visual impact when tinted solar control glasses are specified, besides achieving better thermal insulation. HansenGlass’s Technical Advisory Service (TAS) greatly assists specification from architects, providing advice on loadings to ensure the glass is suitable for the applications. Besides ThermoSpan projects, HansenGlass is often called on to manufacture IG units with the commonly used clip-together rail system for structurally glazed frameless systems.

Toughened laminates

HansenGlass creates laminated glass using a resin pour system (CIP), and prefers to buy in PVB laminated, to free up capacities on machinery helping to sustain consistent output levels. HansenGlass is therefore able to offer both PVB and CIP, quickly and cost effectively, to the customer’s requirements.

‘There is a worrying trend for PVB to be used in preference to toughened or CIP laminate’, says Kristian Kolby. ‘This is often unnecessary as the actual purpose of laminate is not considered but still specified, adding cost to the overall project. Our ‘TAS’ team can help in ensuring that the glass used is suitable for the application.’

Lean manufacturing

The recent investment was also an opportunity to re-organise the management structure and move towards lean manufacturing which is supported by the in-house process of Team Enterprise which focuses on Leadership, Culture and Process. Continuous improvement projects look at processes and try to remove all waste that is identified. Self-directed teams on the factory floor are kept aware of performance and involved in problem solving. There are champions for Quality, Health & Safety, and so on. The company supports staff in gaining qualifications, from GCSEs to MBAs, and there are NVQ internal assessors and verifiers for the staff.

‘We’re a very flat organisation in the way we operate on the factory floor. It’s basically about empowering people to take responsibility for the business.’ says Mark Towers. ‘All factory personnel can drive a forklift and operate a crane as part of the skill step scheme that allows people to develop within the business.’

The company is an Investor in People, an Investor in Excellence and a finalist in the North West Business Awards. HansenGlass is ISO 9001 accredited and is now looking at ISO 14001 Environmental Management.

Group behaviour

The Danish based HansenGroup is a familiar name in construction, and it’s no surprise that the Kirkby factory supplies sister companies, including PollardHansen (fire control and entrance specialists), MAGHansen (curtain walling) and FendorHansen (fire and security screens). Greater sales of ThermoSpan to the Scandinavian based sister companies is a target for the Liverpool business.

The future

The success of London’s 2012 Olympics bid was announced during my visit. In due course, the accompanying construction will comprise many projects that HansenGlass is set up to service – big projects involving large orders for facade glazing, balustrading, partitioning and large IG units.

‘We work with contractors to provide 1,000 piece orders, co-ordinating precise deliveries correct and on time.’ adds Kristian Kolby. ‘HansenGlass is focused on delivering glazing products to larger projects, but similarly have a foundation of smaller accounts who provide a valuable contribution. The mix of these customers is essential and is all based on relationships and understanding the individual customer’s needs.’