The Bardon, Leicestershire-based company implemented the programme, which combines lean manufacturing with Six Sigma, a set of statistical tools used to better understand the way a business operates, a year ago.

Each piece of equipment has its own record book and each operator their own individual programmes. Statistical analysis boards are in place throughout the production area so staff can see how each area of the business is performing.

According to operations manager David Midgeley, the implementation of Lean Sigma is a four-year process, with the first year about "getting the basics in place". However, he said that results were already beginning to show through.

"We have already seen a double-digit improvement in terms of printed sheets on the floor, and that is a key measurement for the overall success of the business. Once you can demonstrate that sort of improvement, both senior management and team leaders around the factory are on your side."

As well as production improvements, Midgely added that the programme would lead to further environmental benefits.

Additionally, a training plan is being formulated with Loughborough College, with all employees invited to take part, which will lead to NVQ level 2 and 3 awards. The first round is expected to begin in January 2011.