‘Leaner’ future in store for Gas Sensor Company

The initial five-day workshop introduced the theory of LEAN and how to apply it in a ‘live’ business environment; this was followed by three days of hands-on project support to assist with the implementation of any projects identified in the initial workshop.

DDS, an electrochemical gas sensor manufacturer and was keen to improve efficiencies within its processes. As a result of the LEAN training, the firm undertook a major change in the layout of its production processes and introduced a number of new standardised processes including problem solving, Statistical Process Control quality analysis, equipment concern reporting and follow-up, and accident near miss reporting.

An accident status display was also introduced, as well as quality concern visual aids and a LEAN communication board displaying the output of the newly installed processes and progress against the LEAN initiatives identified, which initially totalled 19 improvement opportunities.

This was the first time the company has ever undertaken any LEAN training, Roger Davies, Production Manager at DDS commented: “I am delighted with the results so far. We now have a significantly revised and improved Production layout, reducing movement and contributing to team working and I’m sure we can now build on these results through continuous improvement as we move forward.”

Bryan Palmer, LEAN Consultant with Fedden USP believes the training has given the team confidence to pass on what was learnt to colleagues, meaning further process improvements in the future:  “It was a pleasure to work with the team at DDS who were all keen to learn about the LEAN techniques from the outset.”