Turning the Tables Saves More than $200,000

Who knew a bin of scrap materials could save DENSO $223,000? Ron Carr made this happen on a global innerfin condenser (GIC) production line at DENSO Manufacturing Michigan (DMMI) in Battle Creek.

Ron’s idea took just one hour to build, but it’s had tremendous impact. He used leftover SUS materials to build a lazy-susan turntable that allows associates to rotate cores easier and faster. A sensor in the middle of the turntable also helps parts move when associates are ready for the next step. This has helped reduce cycle time, in addition to improving safety and reducing the risk of repetitive strain injuries for associates.

Ultimately, Ron’s idea reduced both the number of people needed to build the part and the time it takes to build it. These savings really add up! In addition to saving DENSO $223,000 per year, Ron also submitted the idea to the DMMI associate suggestion program called BEAM—Because Every Associate Matters. Through BEAM associates receive a portion of the cost savings for one year. Ron’s turntable idea earned him over $8,000.

“My family loves to take trips together, so this money will help us do that,” Ron said.

Ron was also able to crossline his idea to new GIC lines. During his four years as a DENSO associate, he submitted multiple BEAMs before moving to his current Team Leader position, and says that submitting a BEAM is a fun way to stay engaged at work.

“I encourage my Subleader and Machine Tech to do a BEAM every year. It’s an awesome program and there are a lot of people with great ideas out here that could be implemented.”

Associates with a great improvement idea to share can contact Associate Relations or the Manufacturing Improvement Team to learn more about the BEAM submission process.