Rapid Response, Real Results: How Barton Cold Form Prevented a Line Shutdown in Under 6 Days

When a technical error threatened to halt a major OEM production line, time was of the essence to solve the supply problem. However, Barton Cold Form, Optimas’ UK division de fabrication, dealt with the challenge with a rapid response. The power of local, in-house manufacturing reduced the six-week lead time into less than six days. 

This is the story of what happens when Optimas is trusted to handle the complexity of global supply chains. 

Challenge: Production Line at Risk 

It was a Wednesday evening in April 2025, just past 8pm, when an urgent phone call came through to the Optimas UK team. 

A technical IT error on the customer’s end resulted in the stock of externally threaded fasteners to reach a dangerously low level. Production at the major OEMs facility was projected to stop within a week unless parts could arrive in time.  

These fasteners are essential components required for high-volume production. The Optimas UK team needed to act fast due to the fact the normal lead time for these parts was six weeks.  

In times of manufacturing emergencies only one thing matters to Optimas – keeping the customer’s line running.  

Solution: Full-Throttle UK Manufacturing 

With a clear directive from Optimas CEO International, Mike Tuffy: “Do what you have to do ensure the line doesn’t stop”, the team at Barton immediately adjusted production plans and launched into action. 

1. Tooling Turnaround

A full tooling changeover was required. This process would normally account for eight hours, but the team completed it in just four.

2. Overnight Production

Teams were mobilized rapidly, with staff working on-call from home, through the night to ensure the job was complete. By midnight, the first batch of parts were already rolling off the line. By dawn, Barton had produced an entire week’s worth of stock. 

3. Local Supply Chain Collaboration

Barton’s strengths lie not just in its internal capabilities, but also in its proximity to collaborate and operate with trusted, local subcontractors. Within a 30-mile radius, specialist partners were contacted to handle plating, phosphating and hardening – all within the same day.  

4. Inspection and Delivery

The parts were inspected to ensure they met the necessary quality requirements and were packed over the weekend. By 6am on Monday, the fasteners arrived at the customer’s site. 

Outcome: From Six Weeks to Six Days 

Thanks to the manufacturing agility of Barton, the customer experienced zero downtime. 

• Lead time reduced from six weeks to less than six days.
• No line stoppage.
• Full customer satisfaction and recognition of Barton’s agility.

In a sector where delays can be extremely costly, Barton’s swift actions safeguarded both productivity and partnership. 

Why It Worked 

The success of the rapid turnaround wasn’t by chance. It’s part of Optimas’ long-term strategy. 

“This is what UK manufacturing excellence looks like – fast, focused and deeply connected to our local supply chain.”  

• Mike Tuffy, CEO, Optimas International

Barton Cold-Form is built for responsiveness. As part of Optimas’ investment in onshoring/nearshoring and reinforcing UK manufacturing, Barton operates with an integrated approach. From designing and producing tooling to final inspection of the finished product, everything is carried out on-site or with local partners. 

Nearby fastener manufacturing reduces risk and increases flexibility. As Barton have shown, when an emergency occurs, there’s no dealing with time zone gaps, international shipments or custom delays.  

 “At Barton, we operate as one cohesive unit, when a challenge arises, everyone aligns with a shared purpose. That’s the strength of our team.” 

• Frank Walsh, VP Manufacturing

About Barton Cold-Form

Based in Droitwich, Barton Cold Form specializes in the production of externally threaded fasteners for a wide range of industries. As Optimas’ UK manufacturing division, Barton delivers high-quality components with speed, consistency and technical precision. 

Barton provides Optimas’ UK and European customers with in-house fastener design, engineering and production capabilities. With over 90 years’ experience in meeting customer’ bespoke fastening requirements or providing standard fastener solutions, Barton can optimize your product’s performance.  

Contactez-nous if you would like to find out more about the capabilities of Barton Cold-Form or to get in touch with how you can partner with Optimas.