Manufacturing overhaul for OEM product lines at Gems

Citation

(1999), "Manufacturing overhaul for OEM product lines at Gems", Sensor Review, Vol. 19 No. 1. https://doi.org/10.1108/sr.1999.08719aab.005

Manufacturing overhaul for OEM product lines at Gems

Manufacturing overhaul for OEM product lines at Gems

Keywords Kaizen, Manufacturing

Gems Sensors' UK Division, previously known as Trans Instruments, was introduced to a new business strategy when the Danaher Corporation acquired it, last year. Originally developed by Toyota, in Japan, the Kaizen philosophy of management has enabled Gems Sensors to invest in new product development and to deliver enhanced service, through improved quality, efficiency and delivery.

Kaizen, which translates as "continual development" in Japanese, has provided the basis for an overhaul in the way Gems Sensors works ­ the most significant changes being seen in the manufacturing area, where the company has shifted from a traditional batch manufacturing set-up to cell manufacturing.

Cellurisation ensures machines and processes are grouped in a pattern that supports flow production. The result is a dramatic increase in efficiency leading to improved and consistent lead-times. Each product now moves from operation to operation in the smallest possible increment and a system of "one piece flow" ensures that only quality pads are allowed to move to the next operation. The individual operator has ownership of each piece, ensuring a high level of quality at all times.

Before Kaizen, a greater number of operators were required to travel longer distances between each workstation. The simplified operation has delivered a staggering increase in productivity, as well as reduced inventory and increased stock turns. All of these changes allow ongoing investment in new product developments, such as the new psibar pressure transducer range, designed specifically for the OEM market (see Plate 1).

Plate 1 Typical psibar sensor manufactured in new Kaizen-based facility at Gems Sensors' Basingstoke plant

With its heavy-duty diaphragm, thermally stable strain gauge and preprogrammed temperature compensation, the psibar offers a rugged solution for demanding hydraulic and pneumatic applications. A wide range of pressure ranges, signal outputs and fittings is provided, while high over-pressure capability protects against pressure shocks (or spikes) ­ usually caused by "pump ripple", "water hammer", or flow surges.

As the company is no longer limited by batch processes, it can also be more responsive to clients' demands. Products can be customised to meet specific requirements and flexible delivery arrangements can now be made for the company's range of flow, level and pressure devices.

Gems Sensors has over 40 years' experience in manufacturing and supporting a variety of pressure, level and flow monitoring control systems, and has achieved ISO 9001 approval. The company's products are used in a variety of applications, ranging from water, general machinery and OEM applications, to marine, power and process control.

For further information contact Gems Sensors, Lennox Road, Basingstoke, Hampshire RG22 4AW, UK. Tel: +44 (0)1256 320244; Fax: +44 (0)1256 473680.