Case Study Business Action Learning BALT

Petuna - Order Fulfilment Project

Objectives:

  • Identify areas for improvement
  • Reduction in Frozen WIP
  • Improve Production Planning
  • Remove ‘business silos’ and improve communication • Improve customer complaint management
  • Accountability for cross departmental responsibilities • Integrated Systems

Key areas:

  • Harvesting and selling to plan
  • Complaints and credits dealt with in a timely manner • Staff utilisation
  • Frozen WIP
  • Performance against departmental responsibilities
  • Development of integration tools

Outcomes reported:

  • Frozen WIP maintained at a planned level
  • An integrated planning tool developed
  • Regular team meetings occurring between various stakeholders
  • Production and staff allocation planned more efficiently
  • A customer complaint process documented for use by sales and QA departments
  • Roles and responsibilities template developed for use by departments in future process reviews
  • Clever use of data integration, with the new planning tool and other integrated features complementing investment in systems in the business

“The best aspects of the program were the project scoping, which was very consultative and well thought out. Also, the input from other companies, professional facilitation, networking with other senior management, and having our employees visiting other companies and vice versa. We are now in the final stages of development of a business tool for tracking fish allocation by size class and quality to individual customers, which was a direct outcome of the project.”

Mike Thomson, General Manager
Petuna

Harvest Moon - Onion Processing Project

Objectives:

  • Analyse the characteristics sought by Harvest Moon’s onion customer base
  • Produce a target crop profile
  • Examine the value chain for the onion production system identifying ways to improve its efficiency and effectiveness
  • Install new packaging equipment and reconfigure the processing, grading and packing line in order to improve the efficiency and effectiveness of the line

Key areas:

  • Crop Profile Strategy • Crop Sampling
  • Onion Line Operation • Prepack Location
  • Packing Cell Design
  • Grading and Waste
  • Cool Store Energy Use

Outcomes reported:

  • Crop profile is aligned with customer demand
  • Knowledge retained in-house to change the profile if required
  • Improved ability to pick crops and balance the line to meet customer expectations and efficiency targets
  • 5-10% improvement in labour productivity from new Packing Cell design
  • Maintenance involved in equipment redesign
  • SOPs produced for itinerant employees
  • Product boards used for communication between management and staff
  • Trials found sizing and grading onions before storage provided 10-20% extra storage space
  • New field methods of sun screening has allowed better bin fill rates at harvest
  • Quality information during crop sampling allows selection of appropriate crops to be stored (better outturn rates)

Bell Bay Aluminium/Kempe Engineering - Cathode Tail Project

Objectives:

  • Develop and implement a sustainable and cost effective manufacturing process for the manufacture of 9B type reduction cell collector bar tails for Bell Bay Aluminium
  • Identify possible methods for converting old tails to new design tails
  • Develop a cost effective recycling process for used 9B collector bar tails

Key areas:

  • To produce a competitive priced product against current overseas supplier
  • To produce a product that is equal or superior in performance than imported equivalent, ie. electrical performance, tail lifespan (ability to be recycled), and ergonomics

Outcomes reported:

  • Cost targets met through reduced labour time, improved processing at BBA, increased refurbishing rate, recycling of Type 6 material and the development of Manufacturing Cell Design
  • Majority of materials used are now recycled
  • New concept has improved electrical performance - ongoing mV savings per annum of approx. $40,000+ per year
  • New manufacturing cell design reduces manual handling issues due to reduced movement, mobile equipment use and ease of welding to collector bar
  • Personnel and skill base retained in Tasmania
  • Reduced CO2 emissions due to recycling

“The direct benefits to Bell Bay Aluminium from the program are the creation of value that can be shared versus simply applying price pressure on suppliers.
It strengthens the local manufacturing base that BBA can draw upon, and it provides fresh pairs of eyes that find opportunities inside the gate that may have been overlooked.”

Greg Turner, Manager - Commercial Services
Bell Bay Aluminium

TasRail - Locomotive Maintenance Project

Objectives:

  • Supply the required number of TR locomotives to Freight Services when required
  • Minimise downtime of TR locomotive fleet for scheduled maintenance

Key areas:

  • Time taken to lock on and off
  • Loco Release from Operations to Maintenance
  • Lost time Accumulating Service Parts and Consumables
  • Work environment and availability of services, equipment and relevant documents
  • Duplication of service tasks • Lack of skills-based training

Outcomes reported:

  • Improved locomotive availability for increased revenue
  • Reduced out of service time from 4 days to 3 days for “B” Service
  • Implementation of 5S throughout the workshop
  • Freed up time for maintainers to participate and work on ways to continuously improve practices
  • Improved open communication between different stakeholders
  • LED pit lighting 30% cheaper to run and maintain and improved work environment for maintainers
  • With time saved, maintainers are able to participate in training and fixed plant maintenance