Kewell Converters’ National Manufacturing Day gave students first-hand experience of the technology, skills and problem-solving behind modern manufacturing
There is no single way to solve an engineering problem, as Kewell Converters discovered when it put young visitors to the test during National Manufacturing Day 2026.
Students from The View School in Edenbridge and A-level engineering and design students from Oxted School were among those invited inside the specialist foam converter’s 33,000 sq ft factory on Thursday 24 September.
Rather than simply talking about manufacturing careers, Kewell Converters took students onto the factory floor to experience the technology and processes for themselves and meet people working across different manufacturing roles.
Managing Director Nick Kewell said one of the biggest reactions was surprise at the breadth of what takes place inside the business.
“What really stood out was the level of interest,” said Nick. “They were surprised by the size of the factory, the number of different products we manufacture and the range of industries foam goes into. Once they were on the factory floor, they wanted to understand how things worked and why we do things in particular ways.”
For the A-level engineering and design students, the visit provided an opportunity to explore manufacturing in greater technical detail.
General Manager Neil Johnston led their tour, where the waterjet cutting process and the technology behind it generated particular interest. Discussions also covered specialist applications including acoustic foam, alongside questions about Neil’s own role within manufacturing.
The students met other members of the Kewell Converters team responsible for different stages of the manufacturing process. CAD/CAM Programmer Joel Dallison talked them through the design process, while Quality, Health & Safety Manager Geoff Daniels discussed quality control and health and safety.
The visit then moved from observing engineering to putting problem-solving into practice. Students were challenged to assemble a precision-cut foam cube made from a series of interlocking pieces. The puzzle can prove difficult even when instructions are provided. One student from The View School, a specialist SEND school, assembled it almost immediately without referring to the instructions.
For Nick, the moment demonstrated the value of different approaches to solving problems.
“It was remarkable to watch,” he said. “It was a real reminder that people think and process information in very different ways. Some people have an incredible ability to see a solution that others can’t, and those kinds of problem-solving skills can be hugely valuable in engineering.”
Later, the A-level students approached the same challenge differently. Neil said the group became highly competitive but listened carefully to the instructions and worked through the problem.
Each visitor was given one of the precision-cut cubes to take home.
Nick believes experiences like these can show young people aspects of engineering and manufacturing that are difficult to communicate from outside a factory.
“You can tell somebody what manufacturing involves, but it’s completely different when they can stand in a factory, see the technology working, ask questions and talk to the people doing the jobs,” he said.
“That’s what I find rewarding about opening our doors. You see what captures someone’s interest and sometimes abilities come out that you wouldn’t necessarily have seen in another environment. Engineering needs people who can think, question and solve problems in different ways.”
The impact extended beyond the factory tour, with several students from The View School saying afterwards that they would like to return to Kewell Converters for work experience when they are old enough.
Amy Marchant from The View School said:
“Our students thoroughly enjoyed their visit to Kewell Converters and came away really inspired by what they had seen. They were particularly interested to hear how the business had grown from small beginnings into what it is today, and several have already said they would love the opportunity to return for work experience when they are old enough.”
National Manufacturing Day is organised by Make UK and encourages manufacturers across the UK to open their doors to schools, colleges and communities, showcasing the technologies, skills and career opportunities within modern manufacturing.
