OFS | PGH Case Study
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1st Floor, 10 York Street

Richmond, VIC, 3121, Australia

PGH Bricks & Pavers and OFS partner to find $30,000 a month in savings.

PGH Bricks & Pavers

PGH Bricks & Pavers and OFS partner to find $120,000 a year in savings.

Overview

PGH Bricks & Pavers, a wholly owned subsidiary of CSR and a leader in construction material manufacturing, partnered with OFS to empower their team with digital solutions which create accurate and real-time insights over quality and productivity.

 

Throughout the OFS-Xpress program, the team at PGH Bricks & Pavers have made leaps forward in accounting for production time and output quality, with the OFS timeline providing a gold standard of truth in every reporting activity. Combined with a driven and determined team, OFS have helped PGH Bricks & Pavers Cecil Park to operate more sustainably into the future.

Challenge

 

PGH Bricks & Pavers strive to make world-class products for their customers. To succeed and excel, the team at PGH required:

  • Visibility 
    Accurate and real-time information which decision makers can rely on. 

     

  • Accountability
    Trusted data which can be used to hold suppliers, teams and leaders to account.

     

  • Efficient Tools
    Tools which focus enquiry, and give back time to operators and leaders.

     

  • Sustainability
    Tools which deliver a tangible return on investment within measurable time-frames.

Solution

 

Rhys Hutcheon, Production Manager at PGH’s Cecil Park, NSW site, deployed a 30-day obligation free trial of OFS (the OFS-Xpress Program). Within the OFS Cloud, Rhys has transformed site visibility with a real-time production timeline and used paperless digital factory tools to transform quality processes. 

Engagement with operators is secured within the OFS Console, where production events are logged. Operators were excited by the new consoles, which became part of production processes smoothly in just a few days. OFS has opened up a new channel for operator feedback, with operators sharing their knowledge with every other team in real-time via an annotated event timeline.
 

“It took 3 weeks to go from nothing to 100% visibility, which is unbelievable,
 but OFS made it real!”

Rhys Hutcheon - Production Manager

Results

With complete visibility from the new reporting capabilities, in just 30 days PGH has been able to identify and implement a process change which allows for 6-8 additional hours per week of production. This opportunity is worth $120,000 per year.

PGH has also achieved:

Quality Optimisation  
Optimising Quality Checks has given 10 minutes per hour back to Operators.

Waste Reduction 
Immediate feedback from Quality Checks has resulted in significant waste reduction.

Improved OEE

Operator engagement has noticeably improved, with a day on day OEE gain and a significant improvement in production output.


Increased Visibility 
PGH now have 100% visibility to make better informed decisions, helping their team reduce costs and increase outputs everyday.

The Power of Paperless

 

With OFS-Flow, check sheets have been digitised on the line, creating a fully paperless quality system. Operators now complete the right checks at the right time, notifying the team when corrective action is needed. There’s no more double handling of factory paperwork, and time is saved.

 

“We knew wire changes lost us time, but with OFS we can see the real cost the process

had on our bottom line”

Rhys Hutcheon - Production Manager
 

The Future

 

PGH Bricks & Pavers are continuing to build on the success of their 30 day free trial. Rhys is eager to empower the entire site to improve their daily decision making with real-time OFS data. With the results he has already achieved, Rhys is excited to see the solution expand beyond the Cecil Park site, which would provide visibility across the entire business.

Register for a Free Trial Today
Ready to kick start your Industry 4.0 journey? Register below for a free trial of the OFS software solution, or to click here to contact an OFS Sales Representative to learn more.