“Learn From The Best”
Victorian Manufacturing Hall of Fame 2008 Edition
The Victorian Manufacturing Hall of Fame Awards were introduced in 2001 by the State Government
of Victoria to recognise the achievements of local manufacturers in their pursuit of excellence.
Now in its 6th year, Innovation Insights has facilitated 350 Insight site visits where 5,500 Victorians
from 1,000 enterprises have had an opportunity to ‘Learn from the Best’. Insights to Excellence,
a not-for-profit organisation committed to foster and promote an awareness of manufacturing
excellence and best practice within the Victorian business community, again offers the opportunity
to participate in an Insight visit.
The 2008 Hall of Fame inductees are the feature of this series of Innovation Insight events and will
enable all inductees to showcase their organisation and share their secrets of success.
In a changing and competitive business environment, these innovative enterprises and sustainable
manufacturers utilising advanced technologies and global supply chains, demonstrate a range of
successful business models and approaches to achieving manufacturing excellence.
A common theme of sustainability to enhance an organisations competitive advantage and to
improve business performance and profitability is shared amongst these exemplar organisations.
In 2008, Insights to Excellence presents another Sensei Insight with the theme ‘The Sustainable
Organisation’. Rate yourself against Best Practice on the back page.
More than 90% of organisations that participated in an Insights visit in 2007 have implemented a
business improvement and attributed more than $30M of increased profit directly as a direct result
of participating in an Insights visit … can your organisation afford to miss this opportunity?
Proudly brought to you by
Ecotech
FMP Group (Aust)
Hilton Manufacturing
Aisin Australia
Lumen
Schiavello
Location Knoxfield
Location Ballarat
Location Dandenong
Location Sunshine
Location Hallam
Location Tullamarine
Advanced Manufacturing
Commercialisation of R and D
Continuous Improvement
Lean tools and resourcing
Sustainable Practices
Advanced Manufacturing
Continuous Improvement
Lean Manufacturing
Design Innovation
Continuous Improvement
Research and Development
Advanced Manufacturing
Continous Improvement
Sustainable Manufacturing
For over 30 years, Ecotech’s proven excellence in
design, maintenance and engineering has delivered
sophisticated pollution monitoring systems to enable
customers to maintain a cleaner, safer, healthier
environment.
Founded 53 years ago, FMP Group has grown
to become one of Victoria’s leading automotive
component manufacturers, producing more than
7 million brake parts each year for local and
export markets.
Hilton Manufacturing is a family owned business
in Dandenong, Victoria. They are recognised
nationally as the foremost component manufacture
to the Trucking Industry, servicing all Australian Truck
O.E.M.s
“Quality First”
R and D lead enterprise
In 2006 Aisin Australia introduced the New
Camry Door frame and Frame moulding
production process very successfully as a local
manufacturer.
Integrated and Flexible Manufacturing
Our vision to be a ‘one stop’ environmental
monitoring organisation with the best available
technologies has seen us expand our expertise to
provide reliable and easy to use solutions for Air,
Water, Noise and Emissions applications for large as
well as small organisations.
The longevity and continued success of the
company can be attributed to its 370 strong
workforce, the dedication of its employees, a loyal
customer base and the development of excellent
products and manufacturing processes.
Hilton is a major supplier to the Truck aftermarket
through Distribution in every State.
Lumen Australia is a global supplier of
wiring looms, electronic systems and
plastic components to OEM vehicle
manufacturers and the automotive
aftermarket in Australia and around the
world. With over 20 years experience,
our commitment is to provide creative
solutions which will improve and enhance
our clients products and services with
flexibility, speed and turn-key solutions.
Our experience in servicing, installing, maintaining
and operating all equipment sold has given us a
unique perspective into problem solving and hand
on understanding of customer’s requirements.
This viewpoint ensures Ecotech’s environmental
monitoring solutions are fit for purpose, regardless of
the size, complexity or budget of your project.
Primarily operating from its Ballarat premises,
FMP supplies brake products to 7 out of 10 vehicles
on Australian roads, while its plants in Thailand and
Malaysia support the needs of overseas customers
9am - 1pm
The company is now the preferred supplier to
Iveco, Mercedes, Kenworth, Volvo & MACK and
Western Star of Fuel Tanks, and exports to Tata /
Daewoo in Korea, Hino Nissan & Isuzu in Japan,
Scania in Sweden and Westport in Canada. Hilton
manufacturing also supplies all 14 Australian Truck
Companies with aftermarket products.
14 August 1pm - 5pm
21 August
9.30 am -1.00pm
Learn About
Learn About
Learn About
• Commercialization of R and D
• Providing an environmental monitoring
services and turn key systems to
enterprises and agencies around the
world
• Shop Floor Scheduling
• Score Cards
• Dedicated versus part time continuous
improvement resources
• Sustainability Projects - Waste
Reduction
• How product innovation has been the
driver for 22% compound growth
• How to succeed by constantly
launching new products to replace
imports
• Careful investment in state of the art
technology
www.ecotech.com.au
Aisin Australia is firmly committed to the
achievement of its Vision 2010 based on a
company philosophy of “Quality First” and
development of Aisin Australia to becoming a
“Strong and Valued Supplier” for our customers.
www.bendix.com.au
www.hiltonmanufacturing.com.au
Book on line at www.i2e.org.au
With resources in Australia, Europe, Taiwan and
China, Lumen designs and manufactures a vast
array of products using both the latest computer
aided technologies and the experience of specialist
engineers.
Lumen offers a complete service from the initial
concept development to the final product delivery.
Their manufacturing plant has been designed with
flexible production in mind to accommodate our
customers requirements.
The company is Quality Accredited to ISO9001
and working towards ISO14000 Environmental.
Over the past 8 years an average growth of 22% per
year has been achieved. During this time our staff
levels have grown from 40 to 190.
A truly global organisation, Ecotech has supplied
and installed thousands of analysers, samplers and
systems that monitor air quality and emissions in
more than 45 countries on all continents.
12 August The company commenced business in 1976 and
now operates from a modern factory of 10,000 sq
metres.
This new operation employing around 100
people is a purpose built manufacturing site
featuring a very “Clean & Lean” layout and
Flexible manufacturing processes that supplies
the door frame and door components to the
Toyota plant in Altona.
28 August 9am - 1pm
11 September
9.30pm - 1pm
Schiavello is an integrated global company
offering innovative, interior project and construction
management, and product manufacturing services,
for commercial workspace, healthcare, hospitality,
retail and living environments.
A top 200 private Australian company, Schiavello is
a respected and recognized leader in the creation of
workspace solutions, and in the area of sustainable
environmental practice.
Choosing to go against the outsourcing trend,
Schiavello has internalised the functions of research,
design, engineering, integrated manufacturing and
installation, giving unprecedented control, high
quality output and instant client responsiveness.
Through this unique model, Schiavello services
an ever-expanding geographic network of clients
with customised solution, from its modern production
and assembly facility located at its corporate head
quarters at Tullamarine, in Victoria, Australia (70,000
square meters manufacturing under cover).
30 September
1pm - 5pm
Learn About
Learn About
Learn About
• Lean systems
• Lean layout
• The visual factory
• Poke yoke
• Agile Production • 5s
• How local research and development
leading to world leading technology
underpins 40% growth and growing
exports
• How to keep intellectual property and
profit in Victoria whilst manufacturing
Overseas
• How to get new products to the market fast
• Constant Innovation
• New Product Development
• Commitment to Sustainability
www.aisin.com
www.lumen.com.au
www.schiavello.com
See more Insights at www.i2e.org.au
Injectronics
Armstrong Flooring
SGE Analytical Science
GM Holden
Location Hallam
Location Thomastown
Location Ringwood
Sustainable Manufacturing
Continuous Improvement
Human Resources
Advanced Manufacturing
Sustainable Manufacturing
Lean and 6 sigma
Advanced Manufactuirng
Design Innovation
Sustainable Manufacturing
Injectronics began in the 1980’s as a business
which serviced and repaired late model fuel injected
vehicles.
Managing director Rex Vandenberg, soon found
the need to invest heavily in modern equipment and
specialised training for staff.
Millions of Australians each day walk on an Armstrong
floor. Armstrong is a global leader in the manufacture
and distribution of flooring and ceilings systems.
Founded in 1966 by Ernest Dawes as a syringe
manufacturer, SGE has grown into a global company
manufacturing a wide variety of products for
Analytical Science; specifically the chromatography,
liquid handling, sample preparation and mass
spectrometry markets.
Injectronics soon had many inquiries from other
workshops and dealerships to supply these parts,
and this led to repairing and stocking Electronic
Control Modules so that they would be available on
an exchange basis.
Injectronics is now Australasia’s leading supplier
of quality remanufactured automotive electronic
components. This has been achieved by continually
developing efficient testing and repair procedures
for remanufacturing of automotive electronic
components.
Building on this strong foundation the company
is now researching opportunities with O.E suppliers
and manufacturers. The aim is to provide solutions
to both inventory and warranty challenges using
automotive electronic remanufacturing.
9 October
9.30am - 1pm
As Australia’s leading provider, and only
manufacturer of commercial resilient flooring, we
have plant operations at Braeside and Thomastown
manufacturing commercial sheet flooring, floor tiles
and vinyl flooring accesories.
Recent accomplishements include: one of the top
two recyclers of post consumer PVC bottles using
more than 100 tonnes annually, 32% reduction of
CO2 emissions per tonne of material produced from
base year 2000, a 13% reduction in water use since
2005, use of recycled HDPE shopping bags into floor
tile.
Both plants are ISO14001 and ISO9000
accredited, have Gold Waste Wise accreditation
and are members of the Greenhouse Challenge
Plus. Recent achievement include: Winner of the
2007 medium business Greenhouse Challenge Plus
Award and Keep Australia Beautifull’s Zero Waste
Award, the Keep Australia Beautifull 2006 Litter and
Waste Management Award, and
finalists
during 2005 in the Greenhouse challenge and Save
Water Awards.
16 October 9am - 1pm
Employing around 400 staff worldwide SGE has
its corporate headquarters located in Melbourne
with R&D and production facilities split between
Melbourne and Sydney.
SGE has global customer service and distribution
hubs in Australia, Japan, the UK and the USA, along
with sales/support offices in UK, USA, France,
Germany, Japan, China, India and the Middle East.
SGE has become one of Australia’s most
successful exporters with 97% of revenue derived
from export; it has received awards in many areas
from governments, environmental groups and
technology bodies. SGE is an ISO accredited
company.
23 October 1pm - 4pm
Learn About
Learn About
• Remanufacturing of complex
automotive electronic components
• The Development of specialist
testing and repair test equipment and
simulators
• Exporting of remanufacturing
technology
• The systematic reduction of waste
• Waste wise and Green house
challenge
• The integration of post consumer waste
in products
• How advanced manufacturing is a core
competency at SGE
• A vertically Integrated and flexible
manufacturing model that exports over
98% of product
• Sustainable manufacturing
www.armstrong.com.au
www.sge.com
www.injectronics.com.au
Learn About
Book on line at www.i2e.org.au
Basell Australia
Aerostaff
Location Fishermans Bend
Location Geelong
Location Port Melbourne
Advanced Manufacturing
Continous Improvement
Lean Systems
Sustainable Manufacturing
Continual Improvement
Advanced Manufacturing
Design Innovation
Advanced Manufacturing
Customer Service
Holden Engine Operations (HEO) based at Port
Melbourne, Victoria, produces a range of fourcylinder engines for export and Global V6 engines for
domestic and export markets.
Through significant investment and successive
technology upgrades over the last seven years,
Basell Australia, a company of LyondellBasell
Industries, has doubled production capacity to
130kt/a.
Aerostaff strive to be leaders in Quality, technology
and performance for specialised component
manufacture and assembly in the aerospace
industry.
The V6 engine plant is a $400 million, 32,000
square metre facility that can produce up to 900
engines a day or 240,000 engines a year.
Variants of the Global V6 engine power locally
produced and imported Holden passenger and
light commercial vehicles, including the current VE
Commodore series, WM Caprice Statesman, Ute,
Captiva and Rodeo.
In 2007, HEO produced 269,421 engines and
exported 70% of these to competitive markets in
China, Europe, Korea, Thailand and South Africa
making it Australia’s largest exporter of automotive
components.
During the $150M plant upgrade, improved high
energy efficiency equipment and process design was
used, safety performance improved and an ongoing
community relationship established.
Normal plant production was maintained
throughout most of the project. The plant was
awarded the PACIA Chemicals Industry Sustainability
Award in 2007.
The plant has implemented state-of-the-art
process technology and through planned continual
improvement programmes, increased its quality
performance to world-class levels.
In 2008, the Federal Government’s Equal
Opportunity for Women in the Workplace Agency
(EOWA) awarded GM Holden the prestigious
‘Employer of Choice for Women’ citation for the fourth
year in a row.
Ongoing developments are expected to deliver
further increases in production, quality and efficiency,
aimed at securing Basell Australia’s polypropylene
exports into the Asian market.
30 October 9am - 1pm
6 November Exclusive women’s only tour of
GM Holden’s Engine Operations
Tour limited to 45 women so register early!
Learn About
• Working for an “Employer of Choice
for Women”
• Lean systems
• Advanced manufacturing
• Continuous improvement
www.holden.com.au
9am - 1pm
Aerostaff Australia Pty Ltd is a CASA approved,
AS9100, certified sheetmetal workshop based in Port
Melbourne. We manufacture close tolerance high
precision sheetmetal components and assemblies
for the aviation industries, defense and specialised
Sheetmetal industries
Our Vision is to be the best at what we do best,
we promote continous improvement processes in
order to achieve customer satisfaction with quality,
price and delivery
The use of our in house <Cursor customer
tracking system allows us to conduct business in a
manner which is transparent and supportive to our
customers.
11 November
9am - 1pm
Learn About
Learn About
• Lean Clean and Green
• Sustainability in chemical processing
plant
• How an 85% reduction in energy use
was achieved
• <cursor Internet based customer
tracking system.
• How to promote Continuous
Improvement processes in order to
best achieve customer satisfaction with
quality price and delivery
• How to compete and win against global
competition
www.lyondellbasell.com
www.aerostaff.com.au
See more Insights at www.i2e.org.au
How Sustainable is
your Organization?
Rate your organisation on
the Lean to Green program’s
self assessment scale *
Our % of all incoming materials converted 0
into saleable product (by mass)
< 50 % 1
75% 2
> 95%
The % of raw materials recycled, or made 0
from other companies by-products
<20% 1
50% 2
> 80%
Number of 5R suggestions implemented
(per employee) in the past 6 months
0
None 1
1-3
2
>3
Our products and services assist our
customers to become more sustainable
0
1
2
Not at all Partially Totally
We monitor for all products & processes
the total cost of non conformance
0
None 1
Some Your Sustainable Organisation rating
Total from the above 5 ratings
More than 7/10 C
ongratulations … your organisation is
progressing well on its sustainability journey.
Less than 3/10 Your organisation has opportunity to improve
its competitive advantage and profitability.
2
All
/ 10
* Questions selected from the one day Lean to Green workshop self assessment
The Sustainable Organisation Workshop
The one-day program will include
Overview of the Sustainable Organisation
Presented by Gary Langenwalter
ConfluencePoint USA, International author of ‘The Squeeze’
On-site Waste Walk and Dumpster Dive
Self-Assessment and Action Planning session
Facilitated by Ian Young
DATE Wednesday, August 6th 2008
HOST Carrier Air Conditioning
For more details - register @ i2e.org.au
Innovation Insights
c/o Insights to Excellence Limited
P.O. Box 1204 Kensington
Victoria 3031
Phone: 1800 007 730
Fax: 03 9391 5450
Email: insights@i2e.org.au
Web: www.i2e.org.au