January 7 2002
seals Dynek’s export potential
manufacturer Dynek Pty Ltd has its export market potential all stitched up
with savings of around $160,000 last year after adopting recommendations
by the University of South Australia to improve productivity and
produces some of the finest quality sutures for use in plastic,
cardiovascular and general surgery. While its products are recognised as
the best in the world, Dynek’s productivity and manufacturing processes
were in need of a major overhaul if it was going to stay in business and
be at the leading edge of technology.
Sev Nagalingam and his team of researchers from UniSA’s Centre for
Advanced Manufacturing Research (CAMR) conducted an overall equipment
effectiveness diagnostic study and developed an implementation road map
for Dynek to systematically achieve productivity improvements of 10 per
cent in the short term and manufacturing excellence in the long term.
adopting the recommendations, Dynek’s short-term productivity improved
by 11 per cent. This represented an increase of about 10,000 dozen
products since change over. Additional outcomes are greater control over
production, improved scheduling of operations, staff utilisation and
Company President of Dynek, Mr Barry Crook, couldn’t speak more highly
of CAMR’s research capabilities. “Everything that we wanted to do has
been possible and we were surprised by the savings that could be achieved
in internal efficiencies in manufacturing. In fact we have become so
efficient that we now have the capacity to manufacture far more than we
can sell in our current markets,” he said.
capacity to accommodate both the domestic and export markets had reached
an unsatisfactory situation where the company incurred a loss by
processing an export order ahead of a profitable domestic order, according
to Mr Crook.
our domestic market was healthy and mature, the potential for real growth
was limited. In contrast our export market had the potential for
considerable growth. To be internationally competitive we needed to
improve productivity and increase our output to accommodate larger orders
from overseas without compromising our domestic orders,” Mr Crook said.
methods, capacity planning, shop floor control, layout, material handling
system design, organisation and work space design all came under the
scrutiny of CAMR researchers.
short-term opportunities from the study related to improving layout,
managing work in progress, work procedure design and optimisation,” Dr
recommendations included changing the layout of machinery on tables and
the space for work in progress to accommodate the entire production run on
one workbench. Short-term time savings from layout improvements in the
needle and thread preparation areas amounted to 10 per cent and by
eliminating the duplication of paperwork, a 30 per cent time reduction was
realised. This was achieved by entering stock counts directly onto a
computer and interfacing so that production planning and material
preparation areas could view stock levels.
order packing time decreased by about 40 per cent while overall dispatch
room savings amounted to a reduction in time of about 11 per cent. Staff
levels were reduced from five to two for domestic orders, with three
people for export orders, enabling surplus staff to be transferred to
moving the shrink-wrapping machine so that stock arriving from the
sterilising facility could be shrink-wrapped immediately and put on
shelves ready for dispatch, we saved 11 hours on an ordinary production
run,” Mr Crook said.
part of the ongoing initiatives recommended by CAMR, the research team has
been working on integrating the materials preparation and clean rooms, and
developing an intelligent electronic vision system that will eliminate the
need for manual counting and sorting, resulting in a further $60,000 in
annual savings. The system, costing about $30,000, will be able to sort
eight different products with eight different colour codes, put them into
separate bins, count and label them. It will significantly reduce labour
costs and remove a bottleneck in production, according to Mr Crook.
the long term, we recommend that Dynek continues to improve work methods
and establishes an integrated production planning and control system in
the lead-up to manufacturing excellence,” Dr Nagalingam said.
goal is to help Australian industry become internationally competitive by
developing advanced manufacturing technology, management techniques and
strategies for revitalising Australia’s manufacturing industry. The
centre, led by Professor Grier Lin, has a pool of researchers with expert
knowledge readily available to help industries improve their productivity
and increase profits.”
contact: Geraldine Hinter (08) 8302 0963 or 0417 861832 email@example.com