Benson Group People

December 2010

David Midgley - Operations Manager, Bardon

Having joined Benson Group in August of 2009 following a working lifetime in the textile industry, David Midgley, Operations Manager at Benson Box, Bardon, feels he is now able to describe the benefits that the first year's worth of Lean Sigma has produced for the company, with the obvious highlight being a double digit growth in print production at the company's flagship site in Leicestershire.

"We need to view this as year one of a four year plan to implement Lean Sigma throughout the whole of the plant," said David Midgley. "Year one has been very much about getting the basics in place and getting people to buy into the project. Overall equipment efficiency (OEE) is a key part of the process for a manufacturing company because they can see real results very quickly. We have already seen a double digital improvement in terms of printed sheets on the floor, and that is a key measurement for the overall success of the business. Once you can demonstrate that sort of improvement, both senior management and team leaders around the factory are on your side!"

David comes equipped with a collection of qualifications, including an MBA from Huddersfield University, a technical degree in textiles, and a DMS in Management Studies. He has also, as you might expect, taken part in numerous lean manufacturing courses culminating in achieving a "Black Belt Six Sigma".

Lean Manufacturing and Six Sigma are far from new approaches to management. David has spent the last 16 years applying the Lean and Six Sigma tools to various manufacturing processes, including bullet proof vests, carpets, woven glass, bean bags, bus fabrics, and now packaging printing and production.

Amongst many speaking appearances, David was invited to talk at the Best Factory Conference on matching lean initiatives with environmental projects after a previous company won the Environment Award and was Highly Commended for Best Household Product in 2007.

David is currently introducing Lean Sigma techniques at Benson Box, Bardon, starting with OEE, 5S, TPM, and SMED activities. As part of the overall Lean Sigma programme David is also launching a four-year training programme with a local college. The business is now using Six Sigma as the main problem solving methodology.