Inside Hampton Conservatories
How visual management and smart technology transformed their product manufacturing
Hampton Conservatories, based in Portrush, County Antrim, Northern Ireland, is a British‑made specialist founded in 1982. They design and build bespoke hardwood conservatories, orangeries, glazing structures, garden rooms, and pool houses. Their work spans residential and commercial projects throughout Ireland, the UK, Europe, North America and beyond.
Their approach combines traditional classical proportions with modern engineering. Clients get a hand‑crafted timber extension, using premium hardwoods, triple glazing, ventilation and underfloor heating for year‑round comfort.
Sector: Conservatories
HQ: Northern Ireland
Customer since: 2021
SOPS: 200-300
Other tools: Skills
The Simple Tool That Eliminated Production Bottlenecks
This footage from Hampton Conservatories showcases their innovative magnetic strip scheduling system that has revolutionized their production management approach. Rather than using traditional static boards that require complete rewrites when customer priorities shift, Hampton’s team can instantly reorganize job sequences using flexible magnetic strips.
The system provides immediate visual feedback as conservatory projects move through different production stages, with team members physically relocating strips and updating colors to indicate completion status. The real breakthrough lies in how the magnetic board makes bottlenecks clearly visible, enabling Hampton’s lean-focused team to systematically target improvements where they’ll have the greatest impact on overall production flow.
Key Takeaways:
- Magnetic flexibility beats static boards – Instantly reorganize job priorities without rewriting schedules when customers change requirements
- Visual workflow management motivates teams – Workers get satisfaction from physically moving completed jobs, creating natural engagement
- Bottleneck identification drives systematic improvement – Visual system reveals constraints, enabling targeted lean improvements that boost overall efficiency
QR Codes to Eliminate Setup Confusion
Dwain Steele demonstrates how each molding component now features a QR code that operators can scan to instantly access machine setup instructions through the GembaDocs system.
The visual approach goes beyond just efficiency – gaps in the QR code display immediately reveal which parts still need documentation, turning operator downtime into productive improvement work. He demonstrates how they’re systematically working through their inventory, with their newest greenhouse range components being prepared and labeled with part numbers, section sizes, and material specifications, creating a comprehensive visual reference that eliminates guesswork and setup errors.
Key Takeaways:
- QR codes eliminate setup confusion – Operators scan codes to instantly access precise machine setup instructions, removing guesswork and reducing errors
- Visual gaps drive continuous improvement – Missing QR codes immediately show improvement opportunities, turning downtime into systematic documentation work
- Comprehensive labeling creates self-managing systems – Each component displays part numbers, dimensions, and materials, enabling operators to work independently with confidence
The Right Way to Create GembaDocs: Hampton's 6-Step Method That Actually Works
Rather than rushing to build GembaDocs online, Steele’s team starts with collaborative paper-based sessions involving 3-4 operators who work through each process step-by-step, discussing what they do and why they do it.
This collaborative approach captures the best practices from different operators before digitizing anything. The real breakthrough comes in the follow-up phase, where they video operators following the new documentation, using time-lapse analysis to identify waste and inefficiencies. This video review process reveals opportunities to eliminate significant portions of the original process—in this case, potentially reducing a 36-step procedure by one-third, representing massive efficiency gains for their operations.
Steps:
- Start with paper collaboration – Gather 3-4 operators who work in the area and discuss the process from start to finish on paper first
- Capture collective best practices – Ask “what are we doing?” and “why do we do that?” to agree on the best known method combining everyone’s expertise
- Create the digital GembaDocs – Only after consensus is reached, input the agreed-upon process into the GembaDocs system
- Video operator following the process – Film someone executing the new documented procedure to capture real-world performance
- Analyze for waste using time-lapse – Review the video to identify walking, waiting, and other non-value-added activities
- Continuously improve the process – Use video analysis insights to eliminate waste and reduce process steps, treating documentation as the starting point rather than the finish line
Simple solution to eliminate time and movement waste
This clip reveals Hampton’s innovative use of QR codes to streamline communication between production and design departments.
When operators encounter production issues that require design input, instead of leaving their workstation to physically walk to the design office and interrupt designers, they simply scan a machine-specific QR code.
This instantly sends a targeted form directly to the design department with all relevant details, allowing designers to prioritize and respond appropriately without workflow disruption. The system eliminates multiple forms of waste simultaneously: operators don’t waste time walking and waiting, designers aren’t interrupted during focused work, and production issues get documented and prioritized systematically.
Key Takeaways:
- QR codes eliminate physical interruptions – Production workers can report design issues instantly without leaving their machines or interrupting designers
- Systematic issue reporting improves prioritization – Design department receives structured information and can manage priorities effectively rather than handling random interruptions
- Multiple waste streams eliminated simultaneously – Removes walking waste, waiting waste, and interruption waste while maintaining better communication flow
Visual Management for Complex Machines
Hampton Conservatories demonstrates how they’ve applied GembaDocs to their most complex equipment – a half flapper machine. Rather than letting the machine’s complexity create a barrier for new operators, they’ve created comprehensive video-based training documentation that makes even the most intricate processes accessible.
The visual management system provides complete step-by-step guidance, transforming what was once an intimidating piece of equipment into a manageable training opportunity for any operator.
Key Takeaways:
- Complex machinery becomes accessible – Even the most complicated equipment can be broken down into learnable video steps through systematic documentation
- Visual training eliminates intimidation – Comprehensive GembaDocs transform daunting machines into approachable learning opportunities
- Self-service learning reduces dependency – Operators can independently learn complex processes without requiring expert mentorship for every detail
Authorization System: Who Can Run What Machine (And Why It Matters)
The visual display clearly shows which operators are authorized to use the equipment, identifies training opportunities for others, and tracks which GembaDocs are available versus still in development.
The team strategically uses QR codes instead of traditional displays because the dusty workshop environment makes it easier to keep digital information clean and accessible, demonstrating thoughtful adaptation of technology to real working conditions.
Key Takeaways:
- Visual authorization prevents machine misuse – Clear displays show exactly who is qualified to operate each piece of equipment, eliminating confusion
- Training gaps become improvement opportunities – System immediately reveals which operators need additional training and which processes still need documentation
- QR codes work better in harsh environments – Digital access keeps information clean and readable in dusty conditions where physical displays would deteriorate
