90 workstations replaced in waves around the production schedule.
Tuff Group makes custom 4WD and truck accessories at manufacturing sites in Toowoomba and Brisbane. We replaced 90 ageing workstations across both sites, on office desks and factory-floor stations, in waves timed to the production schedule.
The workstations were out of warranty and parts were scarce.
Tuff Group's workstations had been getting slower for years, all of them were out of warranty, and replacement parts were getting harder to source. The slowdown was costing time across 150 staff.
We put a figure on what the slowdown was costing.
Our engineers had seen the symptoms on site visits, so we brought Tuff Group's management a costed comparison before recommending the work.
Slow workstations were costing roughly 13 minutes per staff member per day, about 5.5 days a year each. Across 150 staff, that lost time cost more than the replacement hardware, and the comparison was the basis on which management approved the refresh.
We specified models already running at other manufacturing sites.
We had deployed the recommended models at other manufacturing clients and seen them run through factory-floor heat, dust and rough handling.
The quote listed those models as options, with the spec picked for the workload Tuff Group's factory stations carry.
Each wave was sized to what the line could absorb.
We took delivery of all 90 units up front, stored them on site, and deployed them in segments that fit Tuff's production schedule and Christmas calendar.
The size of each wave was set by how many stations could be cut over without affecting the line, and Tuff Group set the order of the waves.
All 90 workstations are in at both sites.
The last wave went in before the Christmas slowdown, and the Toowoomba and Brisbane lines ran every shift through the rollout.
Ask us to cost the slowdown in your workstation fleet.
We put a figure on the lost time first, then stage the rollout in waves around your production schedule.