HELIDON, AUSTRALIA — An Australian custom rotational molder has used manufacturing experts to dramatically improve production rates and product delivery times.
It now wants to become truly global and compete in world markets.
Global Rotomoulding Pty. Ltd., based in Helidon, now manufactures eight low density polyethylene water tanks a day when previously it could make only three.
Global Rotomoulding human resources manager Noelene Bellette told Plastics News the dramatic turnaround has also seen the 17-year-old company's ability to complete products within standard industry finishing times increase from an average of 35 percent to 70 percent. Delivery in full and on time averages 94 percent.
Bellette said the company's two factories have reduced costs and time wastage, streamlined manufacturing processes, improved efficiency and boosted employee morale.
When Bellette joined the company she identified there were no simple procedures to keep production running smoothly.
“For example, we had no designated places for keeping tools. That seems minor, but it meant workers were wasting 30 minutes before starting a job while they ran around looking for the right tools to get the job done,” she said.
In 2012, Global Rotomoulding brought in experts from Brisbane, Australia-based QMI Solutions, a Queensland Government initiative to help the state's manufacturers achieve their full potential and compete with interstate and international manufacturers.
A QMI Solutions team audited operating procedures and worked on the factory floor with staff for eight weeks to observe operations and implement improvements.
Global Rotomoulding introduced a range of lean manufacturing and organizational programs designed to improve productivity and better engage staff.
Bellette said since QMI's intervention, the work environment is safer, workers have greater input and the improved manufacturing and delivery times are “beyond expectation.”
But she will not quantify a bottom-line financial improvement, nor will she say how much Global Rotomoulding paid QMI Solutions for its assistance.
The company is still working with QMI to achieve key performance indicators extracted from similar businesses globally and making further refinements to achieve world's best practice in manufacturing standards.
“Now we're proactive rather than reactive and that's made a big difference to how we operate,” Bellette said.
Global Rotomoulding has supplied Australian manufacturing, agriculture and mining industry customers with LDPE water tanks, vehicle haulage tanks, vehicle accessories and custom-molded components since 1998. The company expanded from its sole premises in Victoria in 2007, moving its headquarters to Helidon to be closer to key markets.
