The two companies devised a new workstation built from modular components. They used a process known as spaghetti mapping to identify all of the movements involved in the manufacturing process including the handling of assemblies, components and tools.

This led to a design for the workstation layout. Tubular steel components of varying lengths were then joined using steel brackets to create the basic workstation frame to the precise dimensions identified during the analysis. A bench, wheels, power sockets, lighting and tools including a soldering gun were added to the frame to complete the workstation.

The size and shape of each workstation is optimised for the particular production process for which it is used. They are just the right size and this has helped reduce the size of the production area from 133 to 33m², equivalent to saving 75% of the available space.

Every item has its place on the workstation which helps operatives to maintain a clear and uncluttered working environment but also helps them to identify the correct tool and component. Everything is within easy reach for efficient and ergonomic working. All of the modular components are reusable which means that structures can be modified whenever the application requirement changes or when small incremental process improvements are identified. This ability to adapt and evolve is central to the lean manufacturing concept.

Components for lighting products are supplied to the workstation in the correct sequence and position for efficient and ergonomic assembly using live racking fed from outside the production area using a highly efficient Kanban process. This eliminates the need for stock control operatives to enter production areas so that maximum efficiency is maintained at all times. Extensive colour-coding has been introduced throughout the production area to help staff identify the correct position for the workstations, handling and storage equipment, and even individual items. Cushion flooring installed throughout the reconfigured area has reduced fatigue for staff who spend a lot of time on their feet.

The Tube & Bracket Company assembled the workstations and other handling equipment at the factory in Banbury it shares with parent company Trilogiq before delivering them to Bridlington. The initial reconfiguration of the factory resulted in around half of the site being converted to the new lean manufacturing operation. Britax PMG is currently rolling the concept out across the rest of the site.