Manufacturing Case Studies

  • 5S Implementation - Manufacturing Plant

    As part of a broader improvement project focussing on change over (SMED) time in a specific area of the facility, it became obvious that a key factor inhibiting the achievement of the project goals was the efficiency of the work area.
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  • Change Management for Plant Closure - Manufacturing Plant

    Changes in market conditions necessitated the closure of a major manufacturing site.  The nature of the product meant that maintaining quality up to the date of closure was critical. The announcement of the closure stimulated last minute demand from some key customers.  This required the maintenance of productivity levels up to the date of closure.
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  • CMMS Selection for Implementation - Recycling Plant

    Our client is Australia’s leading construction and demolition materials recycler with six major recycling centres in Victoria and Queensland. EnterpriseIS was engaged to assist them in developing the required maintenance work business processes to support the new maintenance philosophy and then select a CMMS that would support the new business processes and the organisation, as it strived to implement improved maintenance practices.
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  • Defect Reduction - Pipe Manufacturing

    The client was Australia’s largest manufacturer of Oil and Gas pipe. Customer feedback, competitor capability and high rework rates required the capability of the end-machining units to be dramatically improved.
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  • Maintenance Tactics Improvement - Cement Plant

    Our client's business had completed a step change program with the focus on improving ‘bottom line’ performance.  One of the areas of improvement this program identified was the need to improve the quality of the existing Preventive Maintenance (PM) strategy and tactics used on site.
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  • Mistake Proofing - Manufacturing Plant

    The welding process was the heart of the pipe manufacturing process.  It was quite literally, what held it all together.  It allowed flat steel strip to be made into hollow tube capable of withstanding the extreme pressures involved with transmission of natural gas from gas fields to major markets. Rework and reject levels associated with defects emanating from the welding process were unacceptably high.
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  • Process De-Bottlenecking - Pipe Manufacturing

    The client was Australia’s largest manufacturer of Oil and Gas pipe. Market pressures and delivery timeframes for some specific customers meant that increased throughput without additional production shifts was required.
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  • Process Optimisation - Steel Recycling Plant

    The client operates several metal recycling facilities that separate recoverable materials into 3 streams; ferrous material, non-ferrous material and non-metallic material. During benchmarking exercises, it was found that the level of non-ferrous metals in the non-metallic stream was several times higher than best practice.
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  • Product Changeover Improvement - Manufacturing Plant

    The client was Australia’s largest manufacturer of Oil and Gas pipe. Excessive Product changeover times were significantly reducing operational time and availability of the plant. 
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  • Standardised Work - Manufacturing Plant

    During the implementation of an improvement project focused on the reduction of the level of defects, it was found that the accuracy of the categorised defects used as the fundamental basis of the project was flawed.
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  • Total Productive Maintenance - Manufacturing Plant

    Excessive unscheduled equipment downtime in the Plate mill was causing severe slip in the production schedule.  This in turn, was causing delivery performance problems.
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  • Visual Management - Manufacturing Plant

    Lack of alignment in information systems, lack of communication structure and ineffective forums for periodic review of performance, were preventing the ability of the management team to have a clear view of the outcomes achieved by the business.
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