Researching and Implementing a New Product Development capability

The Challenge

ARC Building Solutions are a specialist manufacturer of cavity fire barriers and cavity closers based in Leeds, West Yorkshire. Founded in 2008, the award-winning company has gone from strength to strength demonstrating an impressive growth trajectory. ARC has an excellent reputation in the new build construction industry with leading house building businesses such as Taylor and Wimpey among their key customers.

The 24-month KTP project was built upon a previous collaboration between Leeds Beckett University and ARC Building Solutions where the Retrofit Eaves Insulator (REI) was created. This invention allows homeowners to make their properties more efficient and cost effective by reducing thermal heat loss. The need to bring this concept to fruition has never been more apparent as customers are now significantly more conscious of reducing their carbon footprint by ensuring properties and homes are cost effective. ARC prioritises bringing unique and innovative products to market specifically designed to deliver safer and more sustainable buildings.

In order to start planning for the success and growth of the KTP project, a set of key objectives were identified which included:

• Providing ARC with a rigorous and proactive methodology for new product development in the retrofit and new build housing sectors.
• Facilitating ARC to innovate, expand into new areas, experimenting with new designs and materials.
• Growing ARC’s position in the sector and extending their capability into new markets through new product development capabilities and the development of more strategic relationships with key partners.

The approach

The Associate for this project, Dr Alex Boote, worked closely with Leeds Sustainability Institute Research Fellow Dr Kate Morland and Reader Dr Jim Parker during the product lifecycle stages of the Retrofit Eaves Insulator (REI). The academics inputted their expertise and knowledge around New Product Development. Leeds Business School academic Paul Rhodes played a key part in this project, providing critical insight into the most effective marketing methods when launching the product. 

The patented Retrofit Eaves Insulator (REI) was used as a first concept which helped to facilitate a New Product Development pathway for the KTP project. Prior to the KTP, ARC did not have the dedicated means to identify, investigate, analyse, and then create bespoke new products through the full product lifecycle. It meant that the business lacked aspects of control over the product development phase having to liaise with external partners and manufacturers to bring products to market. By implementing an in-house product development system, it will allow ARC Building Solutions full ownership of the entire lifecycle from start to finish making their supply chain position significantly stronger.  

The impact

Alex’s impact for ARC Building Solutions has been key to their success – he dedicated significant time and resource into the development and planning for the Retrofit Eaves Insulator (REI) to ensure the product launch ran smoothly. Alex used thermal simulations to analyse overall efficiency of the product as well as the production of a quality jig to provide a detailed guide on how to properly maximise the effects of the Eaves Insulator. Once the product was nearing its launch to market, a strategic marketing campaign was created working with Leeds Beckett University Masters students to find the optimum method to bring the product to market. 

Alongside the Retrofit Eaves Insulator (REI), another new product was brought to fruition in the form of the TCB Square. The TCB Square is a cavity fire product intended to stop fire spreading into the cavity from penetrations in the timber frame system houses. This involved preparing reports for test data, applications for patents and design rights as well as the production and marketing elements. 

The launch of the in-house New Product Development is estimated to bring substantial financial growth for ARC post-KTP as the business capitalises on their unique opportunity. This in turn has provided ARC with the in-house NPD and embedded marketing capabilities to become leaders in the promising retrofit building industry. ARC's commitment to continuous research and innovation of products will be taken to an enhanced level by working with industry experts to achieve this.  

Alex made full use of the generous personal development budget while delivering the KTP project. Having started the project with impressive academic credentials in engineering, Alex recognised the opportunity to widen his skill set by completing both a full Agile Project management qualification and a Certificate in Marketing. Alex has also become a Six Sigma Yellow Belt. Other development opportunities include attending a Festival of Innovation and completing a Creativity Ninja course. Alex also learned French.

ARC recognised the value that Alex has brought to the company through his successful delivery of the KTP project, offering Alex a permanent position post-project at ARC.