BPS was created in 2009 by Daryl Boyington in response to increasing requests for manufacturing consultation from several manufacturers. Interest from these companies was rooted in the 13 years of experience that Mr. Boyington had working for ZF Lemförder.
During these thirteen years, Mr. Boyington progressed from a Manufacturing Engineer to Senior Manufacturing Engineer and Product Development Engineer within the ball joint and suspension systems divisions. Through these years, the plant Mr. Boyington was employed in saw dramatic increases in product demand, which translated to record levels of throughput. At its highest levels of output, this plant produced at a rate of 72,000 ball joints in twenty-four hours (the highest of any plant in the world under one roof). Great ideas and experiences came from this level of production.
Mr. Boyington contributed to this success with innovative ideas in assembly concepts and methods, such as:
- Multi-use machines for a variety of parts
- Cycle time reduction methods
- Roll to torque
These suggestions helped single machines perform multiple tasks, increase output and reduce the amount of rejected parts. They made Mr. Boyington a valued employee and many considered him a world resource for automotive assembly concepts.
In 2008, Mr. Boyington left ZF Lemförder prior to an impending plant closure, which was due to a corporation initiative to reduce costs by outsourcing production from the United States.
From 2008 to 2009, Mr. Boyington worked in engineering at a construction and manufacturing facility. During that one year, several companies contacted Mr. Boyington for help, primarily automotive supply companies like ZF Lemförder and Multimatic. He helped create an assembly system capable of building a total of 32 different suspension parts, including stabilizers and ball joints ranging in size from 19mm to 35mm. Mr. Boyington designed and built the line from new and existing components in the interest of saving money and time and implemented it into their facility in Mexico in 2010. These consultation requests led to his decision to start Boyington Productivity Systems.
Since its beginnings, BPS has worked with defense contractors, recreational boat builders, cast stone manufacturers, electronics companies and many others. Some companies looking for process consultation help others looking for machine designs for their operations, adding to the BPS clientele.
Boyington Productivity Systems has independently developed a pneumatic safety valve, a school safety alert system, and has worked with the University of Maine’s Advanced Manufacturing Center to provide designs on many projects. A few of these include prototype engines, laboratory equipment, and pellet mills.