Victorian-based Volgren Australia manufactures the latest generation of buses soon to join the commuter fleets of several Australian capital cities. For passengers, the new buses will feature improved comfort and stylish fitouts. For Volgren, they will represent improved processes and results.
Working closely with EGR, Volgren has radically reduced the number of individual components in its buses, whilst improving quality and function.
"Initially, EGR was brought on board to manufacture 1,500mm lengths of ducting to be used in the buses' airflow system," said Nick Dobson, Victorian State Manager of EGR Display. "We are now making 10 internal parts for Volgren buses, and in future we may manufacture exterior parts such as cladding and bumpers."
EGR's first-time involvement in bus manufacture began last year after Volgren conducted a review of its vehicles' internal components. The review identified overseas-made ducting to be a key area where savings might be made. Every 1,500mm piece of duct contained some 50 components! In addition, the ducting didn't transport well and was easily scuffed when handled, and it had to be trimmed and modified before it could be installed.
"While Volgren was keen to improve its processes and reduce costs, it also wanted to support Australian manufacturers wherever possible," said Nick. "The government-run Industry Capability Network got involved and recommended EGR for the job of producing an alternative plastic part that could replace the ducting but perform as well as the overseas product."
Nick said the project was a "natural fit" for EGR and well within capabilities. By combining EGR's capabilities to extrude the raw material, provide engineering input and manufacturing expertise, EGR designed and produced a single ASA-capped ABS plastic component which eventually won EGR the contract.
"We were able to reduce the number of components in the ducting lengths from about 50 to just one," Nick said. "This provided significant improvements in throughput times for our client."
"Another benefit to Volgren was our use of computer-assisted techniques to visualise concepts via a virtual bus. They have used this as an aid to promoting the new system." Following the success of the ducting replacement, Volgren contracted EGR to produce numerous other simplified plastic components for the buses, including front and rear door mechanism covers, a front locker assembly for onboard security, and modern moulded consoles that incorporate all of the bus controls.
In some instances, EGR plastic parts have replaced fibreglass components. The result has been lighter, simpler, colour-fast, aesthetically-pleasing and low-maintenance components.
"After one year, we are now in full production with the bus prototypes being rolled out by Volgren in several cities," Nick said. "All timelines have been met and we have had very positive feedback from the people on the factory assembly floor."
Nick said while a great deal of engineering thought had gone on behind the scenes, the biggest challenge for EGR was keeping production on track.
"Now that the components have been simplified, the manufacturing process is relatively straightforward. We are now concentrating on making sure that everything we produce is delivered on time and to the highest quality standards."
Supply Chain Manager for Volgren, Marcus Downie, confirmed the benefits, citing process improvements, reduced throughput times, fewer quality and freight problems, and greater confidence in the supply chain among the key advantages of switching to EGR.
"We are a little different from many other companies, because for us it's more important to improve the process than to find cheaper parts offshore," he said.
"Our introduction to EGR was unusual but pleasing; and we've been impressed by their technical capabilities. It's been a very good collaborative effort."