Russell Roof Tiles is using artificial intelligence (AI) technology to transform its daily operations. It is reducing the time spent on some processes by more than 50 per cent. The company has invested hundreds of hours over the past 12 months by using AI to develop multiple tools to address the daily challenges faced by its manufacturing and operational teams and improve internal processes.
A new digital quality monitoring system has replaced traditional paper-based quality checks to record data electronically and directly from the factory floor. Production teams and machine operators have real-time visibility of manufacturing performance across its two sites in Burton on Trent. It covers production of tiles and uPVC accessories.
Machine operators can now make any necessary adjustments in real-time during the shift. This is helping to improve accuracy, minimise waste and avoid machinery down time.
Faster access to production data
AI has also been used for its team to access and analyse information held within Russell Roof Tiles’ enterprise resource planning (ERP) system. Instead of manually searching through data, staff can retrieve information easily. They can quickly identify priority orders to focus on the areas that require attention.
Chris Bailey, Group IT Director at Russell Roof Tiles, said, “We identified key challenges that our teams regularly face and discussed how AI technology could boost efficiency.
“We have developed our own bespoke internal tools that are providing our teams with real-time information to work efficiently and make faster decisions. Since the technology has been implemented, it has allowed our teams to continue to deliver the quality and reliability that our customers expect.
“One recent example of how these AI tools can speed up administrative tasks includes one element of our month-end financial reporting. The process previously took around 60-90 minutes each month has been automated to be completed in approximately just three minutes. Machine operators can now update stock numbers in real-time once a production run is complete. This is instead of the production team updating this on the system manually 8-10 hours later.”
AI technology has also been used by Russell Roof Tiles to improve order management with faster access to relevant information. Customers now have clearer, more proactive updates regarding their orders. Deliveries are also being managed more effectively to ensure build programmes remain on schedule.
Chris added, “Our quality manufacturing will always depend on the knowledge and experience of our fantastic staff. We are demonstrating how AI can complement that expertise.”
Sharing AI expertise
Chris has also been invited to speak about the benefits of AI for the company. He will attend SyteLine User Network (SUN) 37th Annual Conference in New Orleans in March 2027. Chris will be sharing his expertise around how the technology is benefiting Russell Roof Tiles’ ERP system. He will also share how it is helping the digital transformation of their manufacturing operations.
Russell Roof Tiles manufactures a comprehensive range of concrete roofing products and accessories for the UK housebuilding sector. The company is renowned for its commitment to innovation, quality, and investment in award-winning solutions. Russell Roof Tiles has redefined what is possible in tile production, delivering improvements in productivity and sustainability.
