Case Studies

Nico Patchay - Niche Modular Construction

Wellington company showing the way for low carbon

The drive for low carbon has rapidly become a focal point for Aotearoa’s construction sector, where the most forward-thinking and innovative operators are partnering with other experts to decarbonise in ways that also deliver biological, ecological, and social co-benefits. One company showing the way is Wellington-based volumetric offsite manufacturing company Niche Modular Construction, whose technical manager Nico Patchay (left)spoke to HERA’s CEO Troy Coyle on the Stirring the Pot podcast about the business’ adoption of HERA’s Zero Carbon Steel program, Hōtaka Whakakore Puhanga Waro, which launched last year in a global first for the construction sector. The offsetting program means there is now a zero-carbon steel option for most steel products used in Aotearoa, noting that the sector has a number of other decarbonisation initiatives in play, including the recently announced plans to construct an Electric Arc Furnace at New Zealand Steel. The program is supported by the work of thinkstep-anz, which HERA commissioned to develop robust program rules to determine the underlying requirements for calculating the emissions for offsetting. HERA’s partnership with Ekos, a leader in carbon management and environmental financing, underpins the administration of the offsetting process, and offsets are sourced from native forest projects in the Pacific Islands. Niche Modular Construction was the first company to use HERA’s Zero Carbon Steel program, and is utilising the carbon offsets to reduce the net emissions of its steel modular building projects, which are primarily classroom buildings. Niche operates in both the public and private sectors and is also exploring the potential application of offsets in modular apartments. Niche currently utilises around 15 tonnes of steel in its builds and has its own engineering department that handles all aspects of the structural steel components. Niche Modular reports the additional costs of using Zero Carbon Steel have been manageable; it bears […]

Waikato company key carbon and stainless steel tube player

Precision component production ignited with 3D Tube Laser Cutter Industrial Tube Manufacturing, located in the Waikato, has established itself as a key player in the domestic market of carbon and stainless steel tube. Their dedication to constantly improving and expanding has enabled them to attain remarkable success in the industry. Bolstering its national reputation as a reliable supplier of high-quality steel tube, Industrial Tube commissioned its game-changing 3D Tube Laser Cutter last year – a one-of-a-kind in New Zealand that has sparked a surge in demand for its services and solidified the company’s position as a leader in the industry. Industrial Tube general manager Ian Foster says the company is proud to have been a cornerstone of the Waikato manufacturing community for almost four decades now, catering to a wide range of industries with its broad product offering and excellent service. “With the market demanding efficiency, versatility and extreme attention to detail, investment in automation and innovation has been a key focus for our business,” says Foster. Known as ‘Pro-Tube services’, Industrial Tube offers 3D laser cutting, CNC Drilling, deburring, tapering, swaging and telescoping of tube, including carbon steel, pre galvanised steel and stainless steel, in addition to its extensive milled tube offering. “Pro-Tube raises the bar in terms of what’s possible in tube processing and manufacturing. New technology like the 3D Tube Laser Cutter, coupled with the experience and knowledge of our engineers, means we can deliver more options and alternatives to New Zealand businesses that are seeking high-quality, customised components,” he says. Since its integration into Industrial Tube’s manufacturing processes, the 3D Tube Laser Cutter has unleashed a wave of opportunities for local manufacturers. The precision, speed, and versatility offered by this cutting-edge machinery have elevated the capabilities of businesses, enabling them to create intricate components with precision […]

Industry 4.0 a game changer for manufacturing at Douglas Pharmaceuticals

Through the power of automation, data analytics, and artificial intelligence, the company have improved operational efficiency, sustainability, and productivity. Using smart technology, the Douglas Pharmaceuticals team are no longer bogged down with manual or repetitive tasks. Now they can focus their efforts on work that adds real value to the business. Watch the video for the full story here – https://industry4.ema.co.nz/ If you’re wondering how Industry 4.0 technologues can help your business, a great place to start is by attending one of the free Smart Factory Showcase events happening around the country during May and June.

EMA & Industry 4.0: Company Profile -RML

RML has been providing high-performance innovative robotic and automation solutions to their customers for the past 40 years. From robotic automation systems, cartoning, case packing, conveyor solutions, custom assembly, palletising, lidders, closers and components. RML has worked with large and small production lines throughout New Zealand and Australia. Problem or Opportunity As a machine builder, RML have identified key issues which were stopping their customers from maximising the value of their investments. Primarily, it was difficult to be connected to machines from outside of the customers’ plant. This led to site visits being required to provide customer support and delivering upgrades that increased customers productivity. The lack of network connectivity also meant that machines were generally standalone, with limited integration with the customers business systems, thus not delivering the performance data to the teams that are. The Solution RML identified that current PLC technology is great for controlling plant, but is lacking in the ability to fully control machines and harness the full potential of Industry 4.0. To make their products Industry 4.0 ready, RML moved to using Industrial Controllers (IC’s) about six years ago. IC’s are similar to a Windows computer. They have the ability to run real-time control and allow a suite of additional programs to be installed, beyond simple machine controls. This has also helped them bridge the common access or security issues which machine builders face with PLCs. Using IC’s, it is now easier to support customers in real-time while ensuring security needs are met. The IC’s allow for the remote adjustment of settings to help when troubleshooting, allowing remote support and troubleshooting, and allowing RML to train new operators online. This ensures machines are back up and running quickly, effectively maximising production. Also of benefit is the ability to collect real-time data using the PLC […]

Upper Hutt manufacturer investing in the future

-Rebecca Reed What started as a small operation out of a shipping container up the back of Kiwi Point Quarry in Ngauranga Gorge, Wellington, has turned into quite the success story for manufacturer Real Steel. Fast forward twenty years later, the company employs more than 100 people and proudly operates out of a 8500 square metre factory site in Upper Hutt. The manufacturing business imports steel out of Sweden and other countries to make steel parts for road transport, forestry, and recycling industries. It also produces a lot of steel for building truck trailers, wear parts, and materials for processing machines. This growth experienced by the company, a family run business, comes down to high employee satisfaction, innovation, and quality service for the customers it serves nationwide, according to owner and Managing Director Luke Mathieson. “We’ve put a lot of effort into focusing on our systems, the traceability of our parts and the way we work with our customers because at the end of the day it all boils down to getting parts out to the customer on time, and being a good, solid trusted supplier.” Real Steel’s efforts were recognised recently at the Wellington Regional Business Awards where they were presented with the Hall of Fame Award, a unique award which recognises and celebrates those enduring businesses that have made significant contributions to the economic and social fabric of Hutt Valley. The awards are given to business who have consistently exhibited excellence in a resilient and sustainable manner over a proven length of time. Investing in innovations With an eye to the future, Mathieson says the company has invested in several innovations including developing and building their own systems and machinery to manage the volume of parts in the factory as a result of rapid growth. “We have thousands […]

Company Profile – Oasis Engineering, Tauranga

Industry 4.0 – Just do it! Oasis Engineering began as the maintenance division of the Gisborne Oasis soft drink brand, before moving to Tauranga and becoming known for its close-tolerance machined parts in difficult to work materials, including stainless steel and titanium. They now make parts for every major compressed natural gas (CNG) company in over 40 countries. Oasis and its team of 30 manufacture precision stainless steel machined and assembled components, primarily for the natural gas industry. We recently caught up with Kevin Flint, General Manager of Oasis, to hear how their Industry 4.0 journey has been progressing. Can you tell us a bit about your background and your role at Oasis? I am the General Manager of Oasis Engineering Ltd. From Blackpool in the UK, I have been in the manufacturing industry for over 30 years. I emigrated to New Zealand in 2006 and I’ve been employed at Oasis Engineering since 2007. I have a degree in Mechanical Engineering, a Masters in Product Development, and am a Fellow of the Institute of Mechanical Engineers (UK). My first professional role was to design Automated Production Machines and write the PLC programs. Industry 4.0 has been in my blood since I began my professional career. Can you tell us what Oasis Engineering do? We are a manufacturing company based in Tauranga with 30 employees. We design and manufacture products for the CNG (Compressed Natural Gas) Industry, Hydrogen Refuelling Industry, Food and Dairy Industry. Currently, 80 per cent of our products are exported to over 20 countries, but mainly the USA and Canada. When did Oasis begin their Industry 4.0 journey? I first became aware of Industry 4.0 after Oasis Engineering was bought by German company, Elaflex Hiby GmbH in April 2017. They have a factory similar to ours in Plettenburg […]

Serious about sustainability? Delve into your supply chain!

-Barbara Nebel, CEO thinkstep-anz Supply chains are ‘having a moment’ – and not an easy one. As a manufacturer, you’re likely to be facing supply chain challenges due to Covid-19 and global unrest. The current situation highlights the critical role supply chains play in manufacturing. Read on to learn how Kawerau-based manufacturer Essity Australasia (formerly Asaleo Care) is future-proofing its supply chain, with benefits to its business, the natural environment and local communities. Zooming out: the global picture and SDG12 But first, let’s start with the global picture. The United Nations’ Sustainable Development Goals (SDGs) recognise that supply chains play a critical role in creating a more sustainable world. In fact, supply chains have their own SDG. It’s SDG 12: Responsible Consumption and Production, and it’s linked to many other goals in the SDG framework. Why the link? Because, by purchasing responsibly, manufacturers can have positive impacts far beyond their own businesses. For example, by ‘buying local’, they can help build sustainable cities and communities (SDG11). By using renewable energy, they can contribute to affordable and clean energy (SDG7) and promote climate action (SDG13). Essity Australasia: SDG12 in action Essity Australasia is a good example of SDG12 in action. The manufacturer produces personal care and hygiene products and is the only New Zealand manufacturer of toilet and hand towel tissue products. The company is serious about understanding and managing its environmental and social impacts, including through its supply chain. Understanding the sustainability of its supply chain Essity Australasia uses Life Cycle Assessment (LCA) to review the environmental impacts of its products across their life cycles. LCAs measure the impacts, including carbon emissions, involved when the manufacturer makes its personal care and hygiene products (using resources like trees, water and energy and services like transport). They also calculate the impacts involved […]

How Tidy International helps float Kingfisher’s boats

When the Mason family bought into a Tauranga-based manufacturer of catamaran-hulled boats, the business management software being used included TidyEnterprise and Xero, critical to the co-ordination and control of their production and supply. After steadily maturing the workflows over the course of the year that followed the Mason family involvement, Kingfisher Boats today enjoys a software system that provides accurate stock and Work-in-Progress reports, with further developments in the works to accelerate overall business efficiency, optimise production processes and deliver company-wide data visibility. Kingfisher Boats is both designer and builder of the Kingfisher range of quality aluminium vessels with catamaran hulls sold through an approved marine distributor network. This growing New Zealand business, with its workshop facilities based in the city of Tauranga, happens to be located in the same city as Tidy’s international headquarters. Kingfisher has built up a solid range of marine-craft products for over 19 years, including commercial and recreational vessels ranging from 3m to 18m in length. Laura Mason, General Manager of the company, comments “what sets Kingfisher Boats apart is our focus on alloy catamarans. We’re unique in producing metal cats under 6 metres with a single engine – delivering a more stable platform in a compact package.” Situation Upon joining the business, Mason soon recognised opportunities for enhancing the manufacturing processes. Applying experience she gained in the automotive industry, with its long history of process standardisation and optimisation; from the production-line efficiency made famous by Henry Ford to Toyota’s Kaizen methodology of continuous improvement, Mason sought to advance the somewhat unstructured approach characteristic of smaller businesses towards a defined and repeatable model. Mason emphasises, “this does need to be differentiated depending on the boat we’re manufacturing. When we’re doing a multimillion dollar 18-metre vessel, there’s a lot of customisation so repeatability isn’t important. But […]

Hutt Valley manufacturer stepping up to fill skill shortages

Like many other industries across New Zealand at present, the manufacturing industry is struggling with a shortage of trained talent due to Covid-19 restrictions on immigration and current work levels. One Hutt Valley manufacturer is taking on this challenge proposing an innovative way to help young people into engineering. MJH Engineering Ltd is one of New Zealand’s leading structural steel fabricators, specialising in the fabrication and installation of large-scale structural steel projects including industrial warehouses, commercial buildings, multi-storey tower-blocks, and seismic strengthening projects. Over the past couple of years, the Seaview-based company has grown in size due to its excellent track record of delivering top quality results and its reputation as one of the preferred steel subcontractors around town. Jeremy Mikoz, HR & Development Manager for MJH Engineering Ltd, says with the demand of projects comes the challenge of finding the right workers. “While there are private training enterprises out there, we’re finding in our industry that many students coming out of these institutions just aren’t receiving the training they need to be ‘job ready’. “On top of that New Zealand is now in one of the worst labour shortages we have seen in the last 10 years which in turn puts more pressure on obtaining talent and solving our work-flow issues.” As a result, Mikoz says they have come up with a solution – the “MJH Welding School.” The school, based at MJH Engineering, would provide a 6-week full-time training course with qualifications to help young people learn on the job skills and theory in welding. At the end of this course, the young people would come out with Unit Standards, a welding qualification, and 240 hours of practical, industry-related training. To top it off MJH Engineering would guarantee the 6 young people with jobs at the end of […]

Women in Engineering: Insa Errey

Insa Errey is a female engineer originally from Sydney who now calls Auckland home. She currently operates as an independent consultant under Curios Sustainability. How long have you been an engineer? Almost 10 years. I was a late bloomer into engineering. What field of engineering do you specialise in? I specialise in Industrial sustainability. My background is in Chemical biomolecular engineering, with my past experiences being in beverage manufacturing. What projects are you most proud of? It is always rewarding to complete large-scale implementations such as fuel switching projects and wastewater recycling projects. But I think my proudest project is more subtle. In my previous company I mobilised employee awareness toward the issues of sustainability and energy efficiency. My campaign drove awareness through cultural change and started a larger shift toward collaboration on energy efficiency. This has seen year on year energy efficiency improvements driving down operational costs, increasing competitive advantage and most of all reducing emissions from their major manufacturing sites across Australia and NZ. Is there scope for creativity, creative thinking? Absolutely. Creativity is the foundation on innovation. I actually went to a performing arts high school, now a long time ago, and I think that is what dew me to engineering was the ability to still be creative and think outside the box but also make significant impact toward system pressures facing us today. What challenges do engineers face in today’s business world? I think that the main challenge facing engineers is that which we are all facing, climate change, and how this is impacting all areas of how we do business. Businesses and, in particular, manufacturing, are facing and experiencing risks associated with operational disruption, impacts of market forces and future stranded assets with the changing energy market. Here I see engineers having the important role […]

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