GM Coachwork’s adapted minibuses remove barriers to mobility and independence 

Driven by a desire to make transport easier for wheelchair users, GM Coachwork was founded with the mission of producing minibus conversions to facilitate people’s lives. For example, the company enables greater mobility for wheelchair users, helps schools overcome logistical challenges, and keeps local communities connected with essential transport. Through its unwavering dedication to remaining at the forefront of innovation, providing affordable solutions, and delivering exceptional levels of customer care, GM Coachwork has empowered thousands of individuals to embrace adapted vehicles daily for improved quality of life. David Vooght, Chief Executive Officer, sheds light on the milestones that led the company to become such a vital part of the community. 

“Formed in 1988, GM Coachwork started as a manufacturer and converter of minibuses. Initially, our original manufacturing site was based in a little place called Dainton, which is not far from our present-day facility in Newton Abbot. For our first ten years, we operated from our Dainton site and experienced steady growth, starting from the ground up. By 1991, we had moved to our current head office in Trusham, where we built a new factory. The following decade, we continued growing relentlessly, prompting us to consider site extension or the acquisition of offsite units for different product lines. As our operations expanded, we ventured into the conversion of small wheelchair-accessible vehicles, predominantly for the Motability scheme. This segment has since evolved into a cornerstone of our business. 

“In a significant move in 2020, we acquired a sizeable manufacturing site spanning 6000 square meters. Located near Bovey Tracey, approximately five miles from Newton Abbot, this site now serves as our main production facility. To sum up, our manufacturing activities are currently divided between the offsite manufacturing area and the Trusham head office, which houses administrative, sales, research and development, and financial functions. In the last few years, I have stepped back from day-to-day management duties within the company, with my son Graham Vooght taking over as the Managing Director alongside his team of directors, Jamie and Steve.” 

Investing in its state-of-the art manufacturing facility near Bovey Tracey was a considerable step forward for GM Coachwork, due to the many benefits its substantial size offer. “This site provided us with the freedom to implement the manufacturing processes and systems we envisioned without being constrained by space and the size of the buildings that may have limited us up until then,” says David. 

Graham Vooght, Managing Director, adds: “I believe that the main advantage of this site lies in the ability to implement efficient and streamlined processes. In addition, it affords us increased flexibility compared to our previous setup across three or four sites, which significantly restricted what we could build and how we could move parts around. Consolidating our operations into this new facility has empowered us to leverage lean manufacturing principles and improve our flexibility in adjusting production volumes for different products. As a result of this strategy, we have been able to maintain operational efficiency and maximize production output.”

But GM Coachwork has not solely focused on expanding and modernizing its production sites. Graham elaborates on how the company is adjusting and evolving in response to the growing electric vehicle market. “While it is growing, electric vehicles constitute a relatively small portion of our overall business. The transition to electric vehicles has only necessitated minimal adjustments in terms of engineering modifications, as our conversions have proven to be quite adaptable to this shift. However, a more substantial focus has been on refining staff training, restructuring human resources responsibilities, and addressing safety issues that revolve around the vehicle batteries and their removal. The handling of batteries is an especially crucial safety consideration, as their flammability presents a critical risk. Extinguishing these batteries if they catch fire is challenging, requiring us to move them from the site or workshop premises to a secure environment. All in all, while integrating electric vehicles has influenced operational procedures concerning battery safety, it has not significantly impacted our manufacturing, design, and engineering processes,” he reveals. 

The push for electric vehicles aligns well with GM Coachwork’s sustainability initiatives, characterized by a commitment to incorporating recycled materials into its products. “Our facility’s roof is equipped with solar panels to generate our own energy when feasible. In fact, we are looking to acquire a higher number of panels in order to boost our energy supply and reduce reliance on the grid. Additionally, we prioritize the use of recycled materials as much as possible. For instance, we transitioned to recycled plastics for about a third of the interior of our Lite bus when it was introduced 15 years ago. We apply the same approach to the wooden flooring and various interior components, striving to maximize our use of recycled materials. Moreover, we engage local suppliers to cut down on travel and fuel expenses. These suppliers have upgraded their technology to meet our requirements, investing in more efficient processes to minimize waste and hit sustainability targets, thus enabling us to offer greener solutions to our customers,” says Graham. 

Looking ahead, Graham shares his vision for the business over the next five years. “While we have explored ventures into other markets with moderate success, we are seeing more potential to expand our market share within the industries we already we operate in, which remains our core focus. A substantial portion of our business, approximately 15 percent, lies in our bespoke services, and we anticipate considerable growth in this area. Whereas we have seen competitors face challenges or lose capabilities, we seem to be strong in this market segment. Beyond that, we expect further success in our mission to train and enhance our workforce, demonstrating our flexibility and ability to adapt. Lastly, we are expanding our partnership with Motability, which has already led to a 50 percent increase in business in the last few months alone. Our goal is to solidify this growth and capitalize on further opportunities within this partnership,” he ends. 

Through continuous innovation, sustainable practices, and a strong focus on customer care, GM Coachwork has empowered countless individuals to embrace independent, accessible transport and lead more fulfilling lives. As it embarks on its next chapter, the company’s dedication to transforming mobility solutions will continue to make a meaningful impact on the communities it serves.  

gmcoachwork.co.uk