Productivity boost draws major clients

With a new workshop, boosted morale and a 100% increase in production, Bundamba-based Brisbane Tray Bodys Pty Ltd (BTB) has caught the eye of major clients, including winning a contract with a global mining, oil and gas company.

Since BTB began working with QMI Solutions in August 2010, it has implemented Lean Manufacturing tools to transform the workspace from a run-down, cluttered shed to an organised, safe, clean work area where the BTB team can manufacture products at double the rate.

BTB manufactures and supplies high-quality steel automotive products, predominantly to the mining industry. Products include heavy duty steel tray bodies; compliant roll-over protection systems; toolboxes; lighting, safety and radio equipment; bull bars, racks and tanks.

BTB Manager Jamie Facer said he first heard of QMI Solutions while working with the Queensland Government in another program aimed at supporting manufacturing businesses.

During his first consultation with QMI, he was introduced to Lean Manufacturing principles that could help BTB become more efficient.

First QMI worked with BTB to develop a production line layout, which considered where equipment, work centres and support facilities were positioned.

As part of the process, Value Stream Mapping (VSM) was used to assess workflow efficiency. QMI created a conceptual design of the factory’s layout, which provided an overview of the entire operation and suggested improvements in positioning work areas and access routes.

VSM is beneficial because it:

• identifies how materials and information flow in their current and potential states
• allows organisations to establish clear, consistent, measurable directions for process improvement efforts
• ensures improvements focus on the entire production process flow
• helps businesses identify inventory and other non-value add activities

Once the facility was reorganised, a 5S workplace organisation system was implemented. Originally developed in Japan, 5S is designed to create organised, more effective work environments. Efficiencies are improved by assigning everything to a specific location to reduce time wasted looking for tools or equipment.

Before and after 5S

Facer said Lean Manufacturing tools had completely transformed the business. “Everything has been sorted into a more organised area; there is more space and everything is in place.”

Within 10 months of QMI Solutions’ intervention, BTB’s production had increased by 100%. “We haven’t measured any other indicators, but we definitely know production has dramatically increased,” Facer said.

Employees have also experienced the benefits. Facer said team morale had increased because workers valued the improvements. “They saw the effort that had been put into upgrading their workspace and it has made it a more enjoyable, safe, clean environment to work in.”

The QMI Solutions consultant who worked with BTB said while manufacturing was always performed in a large shed, the actual workspace was only about 6m2 because old parts and supplies cluttered the work area.

The space has been transformed from a “dirty, dark dungeon” to a “light, airy workspace” that no longer requires lights to be constantly illuminated because the space is now naturally lit. “It looks new. They have painted the floors, there are signs everywhere, and equipment is lined up,” he said.

QMI Solutions helped BTB conduct an enterprise resource planning (ERP) selection process to find software to integrate resources enterprise-wide, including planning, financial management, manufacturing, and sales and marketing components.

Before and after 5S

BTB consequently implemented a manufacturing computer package, which has helped it manage its new-found growth.

Since its improvements, BTB has become a more attractive supplier for major mining clients. For example, BTB had signed a contract to supply mine-specific vehicle products to BHP Billiton. “We now have a safer workshop and it looks a lot more organised, which has enabled us to get bigger
clients on board,” Facer said.

He said BTB would use QMI Solutions in the future, if necessary, but the business had now reached a  point where it could implement further positive changes alone. Management would continue to reassess process improvements and the potential for outside assistance annually. “If we find we need something done or need help in a specific area, we would call QMI again.”

Before and after 5S

Facer said business owners were sometimes reluctant to seek help from third-party consultants because money was a significant issue.

But many did not know QMI Solutions’ specialist services were subsidised by the Queensland Government. “Once owners realise what is available to them, their perceptions of third-party consultants change,” he said.

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