Case Studies

Blending artistry with automation for strategic advantage

-Scott Adams, Argon & Co Manufacturing companies in New Zealand are most often owned, managed, and operated by engineers and therefore they often lack artistry, passion, and flair. I readily, and happily, accept there are exceptions to this statement, but for every exception there are 10 more that focus on precision, performance, and cost. Is this a problem? Sometimes it is, because we miss the opportunity of producing something wonderful rather than something utilitarian, but also because it limits opportunity and commercial outcomes. If we build a low-cost focused, and therefore often automated, manufacturing capability without creativity then it is very difficult to be innovative with product design and it therefore limits our ability to adapt to a changing market or to create opportunity in a new market. I frequently hear that the only reason a product has changed is because the client required it. This is satisfactory for many of our smaller national or regionally focused manufacturing companies as there are significant obstacles to change: there is not enough space, inflexible machinery, or people are scared to try something different. But if we were to examine a list of the NZ manufacturing companies that have been successful globally and nationally, it would be full of companies that have blended artistry with automation, admittedly in industry sectors where that combination is encouraged, which is generally high-value niche products. Another smaller list of successful companies will show they have primarily focused on the artistry. However, we have very few low-cost automation manufacturing companies producing volume that have been successful, primarily because there are too many barriers to be globally, let alone nationally, successful due to our small population and high labour costs. So, if there are benefits in blending automation with artistry then what steps would I take? I’d argue that […]

Q & A with Geoff Necklen of Roadside Supports

What does your company do? We are a steel product manufacturer. . How long have you been in business? 41 years this month. What products do you make? We manufacture our own Roadsign Supports brand range of highway sign pole systems for the NZ market primarily. This includes motorway signage, and urban signage on single post units called Monopoles which are our main products. We are also involved in special electronic poles for bus and congestion management. How are you finding business at present? We have been steady this year but sales volumes are a bit down. I am getting good enquiries, however, and am confident about next year. Where do you source your components? We source all our materials locally from merchants and utilise second-tier suppliers such as profile cutters and galvanisers. Suppliers such as profile cutters and galvanisers. We try to source NZ AUS material as much as possible. Where do you see growth for your company in the future? The roads of national significance and associated new highway projects announced by National mean we have a long-term future with the products we make. The electronics industry is also exciting, and we are right there with many new project solutions with our good client partner.

Oasis Engineering – energy and fuel transfer specialist to the world

From August issue NZ Manufacturer www.nzmanufacturer.co.nz Export award winning, Tauranga based Oasis Engineering continues to expand its international market as a specialist manufacturer delivering world leading solutions to those pushing the boundaries of energy and fluid transfer for the benefit of humanity and the environment. The company originally began as the maintenance division of a soft drink brand but was separated during a restructuring during the 1980’s. The new company quickly established a strong reputation as a machine shop that reliably produced high tolerance precision machined parts in difficult to work materials such as stainless steel and titanium. This led to work manufacturing valves and couplings that were required for the new and emerging Compressed Natural Gas (CNG) fuel market for a major CNG supply company and this quickly expanded to every major CNG supplier and to every significant CNG market in more than 40 countries. Today Oasis Engineering is part of the ELAFLEX Group of Companies of Hamburg and is manufacturing precision CNG, LPG and Hydrogen reticulation products for the world market with approximately 80% of production going to the USA, 10% to other world markets and 10% to the local New Zealand market. The company is well placed to meet the demands of emerging markets including Hydrogen and Methane for heavy transport vehicles and renewable Natural Gas with sales doubling within the last two years. Oasis also produces specially designed high quality fluid couplings for the milk industry trailers. This state-of-the-art manufacturer is fully accredited to ISO 9001:2015 with product testing facilities including a Hydrostatic test rig rated to 4000 BAR and an Environmental Test Chamber rated between -800C and +1850C. A new addition will be a Hydrogen product test laboratory which is scheduled to be commissioned by the end of the year. Meeting the demands for the […]

If we’re all so busy, why isn’t anything getting done?

From MZ Manufacturer magazine, March 2024 Have you ever asked why it’s so difficult to get things done in business today—despite seemingly endless meetings and emails? Why it takes so long to make decisions—and even then not necessarily the right ones? You’re not the first to think there must be a better way. Many organisations address these problems by redesigning boxes and lines: who does what and who reports to whom. This exercise tends to focus almost obsessively on vertical command relationships and rarely solves for what, in our experience, is the underlying disease: the poor design and execution of collaborative interactions. In our efforts to connect across our organisations, we’re drowning in real-time virtual interaction technology, from Zoom to Slack to Teams, plus group texting, WeChat, WhatsApp, and everything in between. There’s seemingly no excuse to not collaborate. The problem? Interacting is easier than ever, but true, productive, value-creating collaboration is not. And what’s more, where engagement is occurring, its quality is deteriorating. This wastes valuable resources, because every minute spent on a low-value interaction eats into time that could be used for important, creative, and powerful activities. Three critical collaborative interactions Decision making, including complex or uncertain decisions (for example, investment decisions) and cross-cutting routine decisions (such as quarterly business reviews) Creative solutions and coordination, including innovation sessions (for example, developing new products) and routine working sessions (such as daily check-ins) Information sharing, including one-way communication (video, for instance) and two-way communication (such as town halls with Q&As) Decision making: Determining decision rights When you’re told you’re “responsible” for a decision, does that mean you get to decide? What if you’re told you’re “accountable”? Do you cast the deciding vote, or does the person responsible? What about those who must be “consulted”? Sometimes we are told input will be reflected in the […]

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 […]

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