
19
Avon Technologies plc
Annual Report and Accounts 2025
Strategic report
Governance
Financial statements
Executing our STAR strategy
Since we launched the Strengthen System at mid-year, it has become
a powerful engine for operational improvement. We’re seeing clear
opportunities to further enhance safety, quality, delivery, inventory
turns and productivity across every site.
During the year we trained every employee on our Strengthen System,
developed 20 proprietary courses for the STAR Academy and took
30 of our senior people to Japan for an intense continuous improvement
training course. We also regularly share learning across the Group from
STAR kaizen events, which are cross-functional projects that take at least
a week. Last year we completed two STAR kaizen per month, which
illustrates the intensity of the change.
Operational KPIs improving:
We set targets of a 35% productivity
increase, a >60% scrap reduction and inventory turns of more than
five in the medium term. Versus H1 2023, when we launched these
targets, productivity has improved by 28%; scrap has reduced by 62%;
and year-end inventory turns have improved by 46% to 3.3x. Average
inventory turns, stripping out the effect of a strong Q4 in 2025, have
improved from 2.8x to 3.0x over the same period.
This year: Average productivity, using the average number of employees
during the year, increased by 8% year on year, demonstrating that we are
delivering sustained improvements in efficiency of direct employees while
materially growing the business. Year-on-year productivity improvement
was broadly flat due to recruitment towards the end of the year to support
growth in 2026. We expect to see further improvement in 2026.
We continue to reduce our scrap rates across the business, with a
24% reduction this year. Avon Protection has significantly reduced
historically high scrap rates in boots, gloves and visors. Team Wendy has
improved quality by training the operators to inspect quality on the line,
encouraging stronger autonomy and problem-solving, providing an
immediate feedback loop if there is a workmanship issue, and avoiding
making lots of products before a defect is found. Quality, operator
capability and throughput all improved.
Average inventory turns improved by 5% to 3.0x in the year. Year-end
inventory turns rose 8% to 3.3x, reflecting our focus on increasing output.
We expect further improvement in 2026, but the first half is likely to
be a mixed picture, with finished good value increasing until the US
Government shutdown ends. This will be partly offset by a reduction
in raw materials as we run down excess stock from the Irvine closure.
Team Wendy DoW production increase:
At our FY25 Interim Results
we highlighted the operational risk in Team Wendy associated with the
ramp-up of our DoW helmet programmes. In Q4, production tripled to
meet this ramp-up requirement. Our primary goal in H1 2026 is to sustain
this improved level of output ahead of driving further growth, but we
exit FY25 with confidence that we will see higher revenue and improved
operational gearing in 2026. We will seek to further improve quality and
productivity on the NG IHPS helmet line and increase production on the
ACH Gen II line by a further 50%.
Strengthen through
continuous improvement
Operational summary
Our STAR strategy was launched in 2023 and set out the
strategic priorities required to achieve our medium-term
goals of at least 5% revenue CAGR, adjusted operating
profit margins of 14–16%, ROIC of more than 17%, cash
conversion of 80–100% and 1–2x net debt to EBITDA.
Our STAR strategy comprises four focus areas:
Strengthen through continuous improvement
to drive sustained competitive advantage
Every day, at every level of our organisation, people are making
small changes that improve our people’s safety, our product quality,
our delivery to customers and inventory reduction. All while also
improving productivity. We call this our Strengthen System.
Transform by creating solid foundations
for growth
Continuous improvement generates cash by reducing inventory
and increasing productivity. We reinvest that cash in growth,
building operations and supporting functions that enable the
business to grow faster.
Advance the business through organic growth
From growing and defending our core and nurturing emerging
opportunities to develop new revenue streams, we can grow our
core business organically – we call this our Advance programme.
Revolutionise: use research, partnerships and
acquisitions to augment our organic growth
And by leading the market with new products, new materials,
disruptive innovation and M&A, we can build a business for
the long term.
We remain fully committed to our STAR strategy –
and it’s delivering. With strong momentum behind
us, we have a packed pipeline of further initiatives
for 2026.