Thorlux Lighting Digitises Safety with Custom Power App

Thorlux Lighting is a globally recognised manufacturer of high-quality luminaires and lighting control systems. Established in 1936 and headquartered in Redditch, Worcestershire, Thorlux designs, manufactures, and distributes lighting solutions for a wide range of sectors, including architectural, commercial, industrial, and hazardous environments.

Before this project, Thorlux relied on paper-based systems to capture and manage incidents, accidents, safety observations, and non-conformances. These manual processes made it difficult to track the lifecycle of each issue, from initial reporting to investigation, corrective actions, and reviews.

The lack of a centralised digital solution created delays, limited oversight, and made it harder to ensure timely communication across the various roles involved in safety management.

As the company looked to modernise, it sought a user-friendly digital platform that could support its compliance needs and provide better visibility across departments.

Following the success of a previous Controlled Document Solution implemented by Valto, Thorlux partnered with us once again to digitise its safety reporting processes.

The objective was to develop a centralised system to manage the full lifecycle of incidents, accidents, and non-conformances, from reporting and investigation through to root cause analysis and effectiveness reviews.

We conducted remote workshops with the Thorlux team to gather requirements and review existing workflows. Using this insight, we built a Power Apps solution, adapting it specifically for incident and non-conformance management.

The app was configured with multi-stage workflows, automated email notifications, and role-based assignments to ensure the right people were alerted at the right time. We also built in flexibility so that roles and notification rules could be updated dynamically as the business evolved.

Throughout the process, we worked closely with the Thorlux team to test and refine the system through extensive user acceptance testing (UAT), accommodating feedback and change requests as requirements shifted.

The result was a comprehensive, user-friendly Power App that has significantly improved how Thorlux manages safety and compliance.

The organisation has moved from a fragmented, paper-based system to a digital platform that streamlines communication, improves traceability, and enhances accountability at every stage of the process.

Automated notifications ensure that incidents are addressed quickly, and the app’s flexibility means it can evolve with Thorlux’s needs over time.

Staff now have a clear, centralised way to report and track safety issues, making it easier to take corrective action and monitor effectiveness.

The project has received positive feedback from across the business and has led to multiple follow-on requests for further enhancements.

Thorlux plans to continue building on this foundation, exploring new automation and integration opportunities to further streamline operations and support continuous improvement in safety and compliance.