Senior Bird Bellows is a leading manufacturer of precision-engineered components for the aerospace and industrial sectors. Known for its high standards in safety, innovation, and quality, the company operates a large-scale production facility and supports a highly skilled workforce of over 200 across multiple shifts.
Case study
The system
Integrated with
Project: Senior Bird Bellows
Engineers high‑performance metallic bellows and flexible joints for high‑temperature and high‑pressure applications
- 200+
- People across multiple shifts
- 20 min
- Previous manual roll call
- < 4 min
- Current evacuation accounting
Chapter 1 of 6
Company Overview
Chapter 2 of 6
Challenge
Before adopting Musterd, the company relied on a manual system during evacuations. Someone had to print a staff list and physically check names at the assembly point. Time was lost waiting for the list to print and working through the names, often taking up to 20 minutes to confirm who was accounted for. This delay posed significant risks in emergencies, where rapid and accurate accountability is critical to ensuring everyone’s safety.
Chapter 3 of 6
Solution: Musterd Roll Call & Evacuation System
Senior Bird Bellows implemented the Musterd Roll Call & Evacuation System, a digital solution designed to automate and accelerate headcounts during fire drills and emergencies. The system integrates with existing clock-in cards, allowing personnel to tap in at assembly points and instantly record their presence.
Chapter 4 of 6
Implementation Journey
The rollout involved thorough testing and close collaboration with Musterd’s dedicated support team. Early minor challenges were quickly resolved with expert guidance, enabling the system to be fine-tuned to the site’s specific needs. This proactive partnership built strong trust and made the system a valuable tool in daily operations.
Results and Benefits
• Faster Evacuation Accounting: Senior Bird Bellows can now account for their entire workforce in under 4 minutes — well within the fire brigade’s expected arrival time — dramatically improving the emergency response compared to manual methods.
• Daily Operational Use: Beyond emergencies, team leaders regularly use the Musterd app to track who is on site and their last known location, aiding workforce management and enhancing overall safety awareness.
• Improved Safety Culture: The system supports ongoing feedback through integrated reporting tools, ensuring issues are quickly raised and resolved.
• Clear, Real-Time Information: Fire marshals benefit from accurate, up-to-date digital reports, reducing guesswork and enabling confident, efficient evacuation management.
• Responsive Support: Ongoing collaboration with the Musterd team has provided personalised support and fast resolution of issues, strengthening the partnership.
Chapter 5 of 6
Testimonial
We’ve seen a significant improvement in our ability to account for people during evacuations. The Musterd system is quick, reliable, and has become an essential part of our daily operations, not just emergencies. The support from the Musterd team has been excellent — they really understand our needs and respond promptly. This system has transformed our safety procedures for the better.
Health & Safety Manager, Senior Bird Bellows
Chapter 6 of 6
Future Plans
Could this be your organisation?
See RotaOne or Musterd working with your own rotas and sites.
Book a demoor call +44 (0) 1993 878 671Senior Bird Bellows plans to continue regular fire drills twice a year and is exploring additional system features — such as role-specific symbols (e.g., first aiders, fire marshals) — to further streamline operations.
