Natural light facility boosts productivity 19% at DPC

Adjust font size:

Manufacturing News, Source : The Manufacturer US
Published : 11 Jul 2002 9:53

Jim Guille, vice president of manufacturing operations at diagnostic instrument maker DPC, says the company’s productivity has increased 19% since moving to the company’s state-of-the-art facility in Flanders, New Jersey.

Although lean manufacturing techniques have been in place at the instrument systems division of Diagnostics Products Corp. since 1992, growth within the company caused several divisions, including engineering and technical customer support, to be located in separate buildings. Bringing everything under one roof was the goal when the company began designing its 80,000 square-foot Flanders facility, which employs 380 people.

Given the chance to start from the ground up, the company gave considerable thought to the lean and environmental aspects of the new plant. “In the design process, we wanted to be sure we recognized flows, how the operation could move efficiently—apply the value-added equation to how we plan to do things,” said Guille. “Before, we had to take separate space in several buildings. Nothing was together. It was terribly inefficient.”

Because a large variety of different technologies are involved in the instrumentation being produced, DPC needs a fluid manufacturing environment. “Our strategic approach is more like a systems integrator than a vertical manufacturer. We have to know a little about a lot of things. Therefore, we have a lot of flexibility in the manufacturing layout,” said Guille.

The floor of the new facility includes utility trenches that run the length of the manufacturing space and contain the power and communications wiring. “We can come up from below and don’t have lots of dangling wires that get in the way of making changes,” Guille explained. “We had a lot of trouble doing it before. We had to reroute wiring and cabling. Even though in the old building we didn’t have things bolted to the floor, it wasn’t as flexible a space. It now takes about half the time to make a change.”

Guille attributes a good portion of the productivity increase to the environment in the new plant, which includes a sophisticated air conditioning system that keeps temperatures even and a great deal of natural light. “We put in skylights so we get a lot of natural light coming from the roof. We also have large vertical window areas. It makes it easier to see, and more comfortable for people,” said Guille.

The results were dramatic, “When we moved in, for the first couple of weeks there was nothing but great big smiles on everyone’s faces,” said Guille. “They were quite happy to be here; they definitely appreciate the natural light. And I think it’s reflected in what we’ve seen in the productivity gains.”