Ned Kenjic, Director and Head of Manufacturing at ASSA ABLOY UKI, introduces MOTUS, the new multipoint lock manufacturing flowline at ASSA ABLOY's production facility in Willenhall.
At ASSA ABLOY, we believe the future of manufacturing is built on innovation, investment and continuous improvement. That's why we've introduced MOTUS – a transformative new manufacturing flowline designed to move multipoint lock production forward and support the next generation of British-made locking solutions.
The first production line of its kind for multipoint locking in the UK, MOTUS represents a significant investment in Yale’s manufacturing operations and reflects the company's commitment to delivering greater quality, consistency and responsiveness for customers across the fenestration industry.
MOTUS – Moving Manufacturing Forward
Derived from the Latin word meaning "to move", MOTUS is more than a production line – it is ASSA ABLOY's vision for the future of multipoint lock manufacturing, reinforcing our continued commitment to manufacturing locks here in the UK.
Developed over a two-year period in partnership with Birmingham-based automation specialists ADI Automation, the 29-metre flowline has been inspired by advanced automotive manufacturing principles and designed to challenge traditional approaches to lock production.
Every product touchpoint was analysed to identify unnecessary handling, movement and inefficiencies. The result is a smarter, connected manufacturing environment where products move seamlessly through production with greater efficiency, consistency and quality.
Combining bespoke automation, manufacturing expertise and real-time performance data, MOTUS creates a more agile manufacturing operation capable of responding faster to customer demand while providing a flexible platform for future growth, innovation and continuous development.
Designed for Today – Engineered for Tomorrow
While MOTUS delivers immediate benefits through improved productivity, consistency and quality, it has also been designed with the future firmly in mind.
The flowline has been engineered as a scalable automation platform with the long-term ambition of transforming raw steel coil into a fully assembled, packaged lock through an integrated end-to-end manufacturing process.
Through intelligent automation and programmable flexibility, MOTUS will ultimately have the capability to manufacture multiple lock variants through software-driven changeovers rather than complex physical reconfiguration. This future-ready approach ensures the line can evolve alongside customer requirements, product innovation and changing market demands.
For customers, this means greater confidence that ASSA ABLOY's manufacturing investment isn't simply addressing today's volumes – it's creating a platform capable of supporting tomorrow's opportunities.
The Power of Data
At the heart of MOTUS is a sophisticated data-led manufacturing approach. Live performance data is captured throughout the production process, providing operators and engineers with real-time visibility of how the line is performing.
This enables faster decision-making, proactive problem-solving and continuous process improvement. By identifying bottlenecks, monitoring productivity and optimising resource allocation, the line continually evolves to deliver improved efficiency and consistent product quality.
The result is a manufacturing operation that moves beyond traditional production methods and embraces intelligent, connected manufacturing principles.
People-Powered Manufacturing
While automation and data drive efficiency, people remain central to the success of MOTUS.
The flowline has been designed to remove repetitive manual tasks, improve ergonomics and reduce physical strain, while introducing station rotation to broaden operator skills and create a more engaging working environment.
This investment in both technology and people helps create a safer, more collaborative and more adaptable workforce, ultimately delivering greater quality and service for customers.
Lockmaster 24 – Built on the MOTUS Platform
Of course, investment in manufacturing only matters if it benefits the products customers buy. Among the products made on the MOTUS flowline will be the recently launched Lockmaster 24 multipoint lock. Combining proven mechanical performance with smart capability, it is the next evolution of Yale’s trusted multipoint locking platform, bringing smart innovation to a product already renowned for its security.
Lockmaster 24 is available in hook and deadbolt variants, with the deadbolt version compatible with Yale SensCheck L2. This enables real-time door status awareness as part of the Yale smart security ecosystem, letting users know if their door is open, closed, locked or unlocked, no matter where they are.
Crucially, Lockmaster 24 supports complete door sets designed to meet the latest PAS 24:2022+A1:2024 requirements, which have now superseded PAS 24:2022 and PAS 24:2016. This ensures customers stay aligned with evolving specification demands, helping to combat modern burglary attack methods.
The Full Lockmaster Range
As well as Lockmaster 24, the MOTUS manufacturing flowline will produce the Yale Lockmaster 21, Lockmaster AutoEngage, Lockmaster 28mm/25mm bifold lock range and Yale YS170 multipoint locking systems.
While all these products are already well established and manufactured in the UK, the new line will enable them to be manufactured with even greater consistency and flexibility than before. There will be improved responsiveness to demand, especially during peak times, and customers will have the peace of mind that comes from knowing the products are supported by a modern, data-driven UK manufacturing operation.
A Century of Heritage, a Future of Innovation
Willenhall has been synonymous with lock-making for generations and remains at the heart of Britain's lock manufacturing industry.
Today, more than 35,000 Yale multipoint door locks are manufactured every week at ASSA ABLOY's Willenhall facility, demonstrating that British lock-making remains a vital part of the company's operations. The introduction of MOTUS ensures this manufacturing heritage continues to evolve, combining generations of engineering expertise with the latest automation and data-driven production techniques.
MOTUS represents the next chapter in that journey, moving manufacturing capability, flexibility, quality and customer service forward, while ensuring Yale remains at the forefront of British lock production for decades to come.
"MOTUS isn't simply a new production line; it's a statement of intent. By combining advanced automation, real-time data and the skills of our manufacturing teams, we're creating a platform that not only improves today's production capabilities but is designed to support the future of lock manufacturing. It demonstrates our continued commitment to UK manufacturing, innovation and delivering the products and service our customers expect from ASSA ABLOY." Ned Kenjic, Director and Head of Manufacturing, ASSA ABLOY UKI
