“TXM is a great learning resource and has played a key role in fostering lasting change in our business.” 

The Challenge

Since the mid-1990’s Branach Manufacturing has developed a world leading range of extension ladders and safety platforms designed to address many of the workplace safety issues associated with accessing heights. Branach ladders are used extensively in industrial and service environments. Branach will also customise ladders and platforms for individual applications.

The popularity of Branach’s products presented the business with opportunities to expand its market in Australia and overseas. However the business was constrained by space, production capacity and manufacturing systems and processes more suited to a much smaller business. Branach’s directors identified the need to improve production and management processes and systems in order to increase productivity, improve customer service and reduce waste and inefficiency.

Branach Managing Director Mike Walsh had been on the lookout for the right help to transform its manufacturing operations. He had worked with Tim McLean from TXM in the past and knew the specialist consulting firm would achieve the results Branach needed.

He was impressed with the breadth of experience and the track record that TXM offered and their approach to change was pragmatic and tailored to each unique environment.

“It was comforting as a business owner to know that TXM had been there and done that and could guide us through a very difficult process. They are a great learning resource and have played a key role in fostering lasting change in our business”, says Mike.

“When you are undertaking a large project you want to be sure you can trust the company you’re working with - we had no worries with TXM,” says Mike.

The TXM Response

TXM used value stream mapping to identify the waste in the Branach Manufacturing process. TXM assisted Branach to develop and implement a new future state for its operations involving:

• Design of production cells for assembly of ladders and platforms
• Establishing a finished goods “supermarket” for platforms
• Establishing a system to level production to customer demand.
• Setting up a system to “pull” ladder profiles and components into the assembly area
• Establishing a “supermarket” to manage the re-ordering of raw materials
• Implementing 5S and visual management to more effectively track the progress of key metrics
• Using structured problem solving and a regular meeting to address persistent shop floor issues

The Results

Branach has achieved significant improvements in operational performance as a result of work TXM has done including:

• Reducing the average assembly time for an extension ladder by 15%
• Increasing average output on the ladder section assembly machine by 50%
• Reducing raw material and component shortages by around 60%
• Reducing order lead time for customers to three days for access platforms and 10 days for custom-made extension ladders

Mike Walsh says the team at Branach were impressed with what TXM achieved.

“We couldn’t have asked for more from TXM - the team delivered what we wanted and so much more. They were professional throughout the project. They became a key part of our team for the entire project.”

“TXM’s professionalism has made working with them a pleasure. They offered the right advice at the right times to keep us on track and generated the motivation for us to keep moving forward. We now see that we too can become a model for other companies, something we would not have considered only a short while ago!”

Branach has increased its overall output by 20% and in the process taken on and delivered the largest order in its history without affecting its service to other customers.

If you want results like this for your company contact TXM today.