AI Adoption Delivers Drastic Time Savings and Improves Manufacturing Quality

A UK roof tile manufacturer is using artificial intelligence (AI) technology to transform its daily operations and improve the quality of its products, reducing the time spent on some processes by more than 50%.

Russell Roof Tiles 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. In turn, production teams and machine operators have real-time visibility of manufacturing performance across its two sites in Burton on Trent, covering 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.

Alongside this, 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 and quickly identify priority orders to focus on the areas that require attention.

AI Boosting Efficiency

Chris Bailey, Group IT Director at Russell Roof Tiles

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 more efficiently and make faster decisions. Since the technology has been implemented into daily operations, it has allowed our teams to continue to deliver the quality and reliability that Russell Roof Tiles customers expect.

“One recent example of how these AI tools can speed up administrative tasks includes one element of our month-end financial reporting, a process which previously took around 60-90 minutes each month has been automated to be completed in approximately just three minutes. Alongside this, machine operators can now update stock numbers in real-time once a production run is complete, rather than 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, resulting in customers having clearer, more proactive updates regarding their orders and deliveries 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.”

Chris has also been invited to speak about the benefits of AI for the company at 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 and helping the digital transformation of its 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. Combining market-leading product design with cutting-edge manufacturing technology, Russell Roof Tiles has redefined what is possible in tile production, delivering improvements in productivity and sustainability.

As an independent UK manufacturer of concrete roof tiles, fittings and uPVC roofing accessories, Russell Roof Tiles provides complete pitched roofing solutions designed for modern construction demands.

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