Son resolves father’s production problems

Kevin Parkin recently led a management buyout at DavyMarkham, with the backing of Leeds private equity house LLP, and his primary focus has been on improving productivity at all levels and engaging the workforce in implementing an effective turnaround programme. So when son Stewart (21), who is studying BSc Computing at University of Leeds’ School of Computing, raised the idea of a university assignment project at the engineering works, Kevin was able to identify a problem that could well be addressed by a computerised solution. “With a full order book at present, we are desperate for extra machine capacity, so if we could eliminate unnecessary bottlenecks and downtime associated with tool changing, swarf removal, overhead crane manoeuvres and routine maintenance, we would have spare capacity to market to customers,” he says. “Previously, we utilised a bar code swiping system to measure general working times and major downtime events, but data was collected at the end of each day, requiring operators to recall details at the conclusion of a busy eight-hour shift. Clearly, we needed a more accurate, real time system.” Thus was born Stewart’s DavyMarkham project, which entailed programming, developing and implementing a Manufacturing Downtime Data Capture & Information System, from scratch. Having prepared an outline proposal, his first task was to make a formal presentation to directors, staff and union representatives at a weekly management meeting, to determine whether the project would be viable and beneficial, at the same time offering reassurances that the system would not be exploited as ‘a spy in the works’. Happily, all parties were enthusiastic about the project and could foresee significant advantages for its immediate introduction, not least freeing up valuable production time. Now completed to Phase 1, the project forms the major plank in Stewart’s final year of computing study. His deliverables on the DavyMarkham project included two software suites, written using the industry-standard Rational Unified Process development framework; a database recording each machine’s total running time, downtime analysis and factory service response; a user manual for staff operating and managing the system; and a final project report, together with a lengthy university dissertation. “Family or not, Stewart has done a first class job,” says Kevin Parkin. “We are now able to record overall machine uptime, analyse the response from production services and, where necessary, invest in additional resources. We shall also be able to accurately plan in advance the service resources required for each job, to ensure more or less continuous machine operation.” “By maximising milling and cutting utilisation in this way, we should be able to accommodate more machining work, which will generate tens, possibly hundreds of thousands of pounds in additional revenue,” he concludes, “which is not bad for a college project!” Pictured are Kevin Parkin (left), with Shop Steward, Brian Straw and Stewart Parkin.