From learning to leading: Delivering real impact on the shop floor

Dacon Fabrications Ltd is a specialist manufacturer focused on delivering high-quality fabrication solutions. As the business continues to grow, increasing production capacity has become a key priority.

Barry Levitt, an Engineering Practice (Manufacturing) Degree Apprentice at the University of Sunderland, is supporting this growth through the application of lean principles and digital tools, demonstrating how apprentices can deliver real impact in a live operational environment.

To support increased production demand, Dacon identified the need to introduce a new laser cutting machine. This presented a strategic decision: expand the factory or reconfigure the existing layout.

Taking this challenge forward, Barry played a key role in supporting a data-driven decision-making process. Applying principles from his degree, he helped assess layout options through a lean manufacturing lens, using quantitative data to evaluate flow, space utilisation and overall productivity.

A key element of his contribution was the development of a to-scale CAD model of the shop floor, enabling the team to visualise and test different layout scenarios before implementation. This approach provided clarity, reduced risk and ensured that the chosen solution – a full internal reconfiguration – would deliver both practical and operational efficiencies.