As one of the world’s leading suppliers of advanced technology systems and components, Denso provide many of the major car manufacturers with products ranging from electronic controls and radiators to filters and instrument panel clusters. The Telford factory is Denso’s European manufacturing site for the production of automotive air conditioning and heating systems.

In October 2003, as a result of new business from Europe and Japan, the volume of parts produced by DMUK’s press section increased dramatically. In preparation for this increase in section output, the existing area was redesigned, with the issue of additional storage taking the highest priority.

After detailed evaluation of the stock levels held at Telford, it was calculated that more than 50 storage racks were required in an area of 1000 square metres. Modifications to DMUK’s existing fabricated storage racks would have been both costly and time consuming, as the level of usage and changeability proved too restrictive.

Working closely with DMUK, The Tube & Bracket Company provided a versatile and cost effective solution. Two types of Lean Tek live storage rack were specified; a single-level unit allowing standard Euro containers to be stacked 5 high and loaded by Lean Tek trolley, and a triple-level unit for the storage of single containers. A pigeonhole configuration was used to ease loading and picking, with each part having its own unique location.

All of the live storage racks and trolleys were assembled at the Tube & Bracket Company’s factory in Banbury and positioned on site in Telford, eliminating the need for an installation team to be present on site during implementation.

DMUK’s Paul Cockayne said “We are extremely impressed with the Lean Tek System which enables us to make continuous improvements to ergonomics and gives us the ability to make immediate adjustments to process changes. Whilst we have previously built racks and fixtures using this system supplied in component form, on this occasion we took advantage of The Tube & Bracket Company’s full design and project management service. The project was completed within a tight 4 week deadline”