A new sense of calm at MAS Mechanical

Since it began working with QMI Solutions in 2010, Mt Isa-based MAS Mechanical Pty Ltd has expanded operations while keeping the business under one roof – something the company never thought it could achieve.

Through its relationship with QMI Solutions and the Queensland Department of Employment, Economic Development and Innovation (DEEDI), MAS has changed its workshop layout and purchased new equipment, which has increased turnover and reduced inventory costs.

MAS is a mechanical, auto electrical and air-conditioning specialist that has been servicing clients for more than 20 years. It focuses particularly on mine sites in the mineral-rich region known as the Carpentaria Mount Isa minerals province, but also extends its services to the Northern Territory. The region has significant lead, zinc, silver and copper reserves and major phosphate and uranium deposits.

MAS’ services range from minor repairs to complete overhauls of all types of heavy and light vehicles and underground mining and earthmoving equipment.

MAS Manager Peter Able, who joined the business in 2010, said MAS heard about QMI Solutions through the DEEDI. "We thought it was good business practice to continually seek ways to improve and expand operations," he said.

North Queensland Manufacturing Specialist Mario Martini, who is fully funded by DEEDI and works closely with QMI Solutions, said MAS Director Max Smith came to DEEDI seeking assistance to grow its operations and capacity so it could increase the services it offered the mining industry. QMI Solutions and DEEDI work together in a collaborative partnership to help north Queensland businesses service the mining industry through varied projects.

"MAS was already doing fabrications, fittings, repairs and mechanical work for mining-specific vehicles, but Smith wanted to extend its services to include maintenance work for industrial radiators," Martini said.

Initially, the business performed a Manufacturing Microscope benchmark exercise in April 2010 to identify and prioritise areas of improvement.

The self-assessment tool measured and compared MAS' practice and performance. It put the business in the 'rich with opportunity' category, which meant it was below 60% capacity for both performance and practice.

Compared with other companies in the transport equipment sector, MAS was 11 points below average in practice and nine points below in performance.

The Manufacturing Microscope found equipment layout was a particular area for attention, especially as a new radiator service needed to be added into the existing workshop. 

QMI Solutions helped MAS introduce the 5S system to improve its workshop layout. Originally developed in Japan, the 5S Lean Manufacturing principle is designed to create an organised, effective work environment as a foundation for other best practices to prosper. The concept involves logical, but not always obvious, changes on the shop floor - sorting equipment, setting it in order, shining or properly maintaining it and standardising and sustaining the approach.

Able said MAS organised the workshop by marking out and colour-coding its floor space. "We put down lines to mark walkways to improve safety and efficiency."

That allowed the available space and workflow to be optimised and eliminated wasted space. Better housekeeping improved productivity.

Martini said integrating a new radiator repair workspace alongside the existing operation was something Smith did not consider was achievable. "He thought there would not be enough space to add the new operation. He just assumed he would have to find another space to do it. But, by re-organising the layout, it could fit."

Able said MAS purchased new equipment to respond to growing operations. The business now houses four hoists, instead of three. "We bought another hoist because we expect to get a lot more business since the expansion."

While Able could not yet quantify the benefits because MAS has been working with QMI Solutions for only a year, he said there had definitely been solid improvements. "We have increased turnover and decreased inventory costs."

Able said the improvements allowed Max Smith to take a step away from the business because it could now function independently. Smith could take a well-earned break because MAS had good systems in place. "His aim was to have the business run by management not him and, with QMI and DEEDI’s help, that became possible,” Martini said.

"Twelve months later, MAS has come a long way and gone beyond his expectations. He has a new-found sense of calm."

Able said MAS would continue using QMI Solutions' assistance in the future, and urged other businesses to do likewise. "Never be too proud to notice you need changes and seek help when you need it," he said.

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