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  • WORKPLACE INSIGHTS STUDY TOUR Victorian Automotive Excellence in Action An Outstanding Opportunity to Experience Best Practice


    Thursday 13 & Friday 14 October 2016

    Pricing (GST included)

    AME Members $490 per person

    Non Member $590 per person


    Lunch (Day 1 & 2)

    Bus (Day 1 & 2)

    Plant Tours of 4 Sites (Day 1 & 2)


    All attendees will need to arrange their

    own flights, accommodation and travel

    to and from the pick up/drop off

    location (city location to be confirmed)


    Register by Thursday 6 October 2016


    Leadership in Operational Excellence

    PO Box 28

    Avondale Heights VIC

    T 1300 263 287

    Join the AME Workplace Insights Tour for a

    practical learning experience. This is a great

    opportunity to ‘learn by seeing’ and ensure you

    experience ‘hands on’ tools and skills to take

    back to your workplace.

    Benefits of the Tour

    The Workplace Insights Tour will provide practical learning opportunities to improve business performance through facilitated Insights to the workplace of exemplar Victorian enterprises. The tour will broaden your thinking and build your knowledge of lean management principles. You’ll experience lean implementation in some of Victoria’s top automotive companies, and develop the understanding necessary to implement these within your organisation. The site visits will feature a detailed examination of the organisational practices of the companies visited and conclude with a facilitated debrief contextualising the workplace experience into actionable takeaways. Each day of the two-day program will include a detailed workplace insight of 2 automotive sites. Attendees can be assured they will come away with clear insights into how best practice is being applied in these companies.

    Companies We Visit

    Despite recent challenges, Victoria’s automotive industry leads in design, engineering and manufacturing excellence, coupled with first-class R&D capabilities and a significant capacity to diversify and transfer into future industries. The tour will visit four exemplar automotive companies based in Victoria:

     Holden Engine Operations

     Nissan Casting Australia

     MtM and Tomcar Australia

     Denso Automotive Systems Australia

  • Highlights from the Tour (Day 1)

    Holden Engine Operations Holden Engine Operations is part of the General Motors global network. GM’s vision is to design, build and sell the world’s best engines. GM Holden has brought together the best, most competitive manufacturing practices from around the world and leveraged what it has learned to develop and deploy its GM-Global Manufacturing System or GM-GMS, a common global manufacturing system for all of its plants. The GM-GMS system incorporates principles such as: People Involvement, Standardisation, Continuous Improvement, Short Lead Time and Built In Quality. The Plant opened in 2003 at a cost of $400 million - GM's single largest investment in Australia for more than 20 years. The state-of-the-art facility gives Holden considerable flexibility in the range of engines it can produce for local and international markets. In early 2014 the plant delivered it's 1,000,000 V6 engine. HEO build more than 34 variants of the High Feature V6 engine for both local and international markets. The Global V6 plant has three machining and sub-assembly lines which prepare blocks, crankshafts and cylinder heads before they are moved to a common line for final engine assembly. Learn About GMS global manufacturing system Focus on right first time Policy deployment Cascading meeting routines 5s and the elimination of waste Flow and balance to TAKT People involvement and CI programs Built in Quality Short lead times

    Nissan Casting Australia In April 2015 Nissan Australia shocked the automotive manufacturing industry by confirming the future of its casting and parts factory is secure “well beyond 2020”. The fresh hope for the facility in Dandenong South was announced after Nissan Australia secured a deal to continue manufacturing parts for the Nissan Leaf electric car and 38 other models sold internationally. Nissan Casting Plant applies Lean thinking, specifically with respect to the adoption of 'Kaizen'. This is extended to developing close working relationships with their suppliers. Nissan Casting Australia’s main business activities are high-pressure aluminium die casting; low-pressure metal die casting and CNC (Computer Numerical Control) machining, assembly and fabrication of a range of accessories. Founded in 1982, the plant reinvented itself as a stand-alone supplier following Nissan’s withdrawal from local automotive manufacturing in 1991. This year, the plant will produce more than two million aluminium castings. The plant exports most of its parts to Nissan factories in Japan, Thailand, Mexico and the US. It currently produces eight core aluminium castings including transmission housings, clutch housings, cylinder heads and oil pan assemblies, some of which eventually return to Australia included in Nissan models such as the innovative Nissan LEAF electric vehicle, Navara pick-up and QASHQAI, Pathfinder, Murano and X-TRAIL SUV vehicles. The castings made by Nissan Casting Australia can be identified by a small kangaroo stamped on the component.

    Learn About

    People Engagement

    Hoshin Kanri

    Team Kaizen


    Visual Management


    DAY 1 8.30am Meet and Day 1 Overview 9.00am Bus to Holden Engine Operations 9.30am Holden Tour and Debrief 12.00pm Lunch 1.00pm Bus to Nissan Casting Australia 2.00pm Nissan Tour and Debrief 4.30pm Bus to Drop Off Point

    DAY 2 8.15am Meet and Day 2 Overview 8.30am Bus to MtM and Tomcar Australia 9.30am MtM and Tomcar Tour and Debrief 12.00pm Lunch 1.00pm Bus to Denso Automotive Systems Australia 2.00pm Denso Tour and Debrief 4.30pm Bus to Drop Off Point 5.30pm Event End Please note the itinerary and times are subject to change.

  • Highlights from the Tour (Day 2)

    MtM and Tomcar Australia MtM is an Australian design and manufacturing company exporting components from Melbourne to the world. Established almost fifty years ago, they built a strong and award-winning automotive background, with a strategy of diversifying from this. They are successfully winning new export business in traditional markets as well as lower labour cost countries including China, India and Thailand. Not satisfied with just components, MtM are now manufacturing vehicles, setting up an innovative manufacturing cell to produce the Tomcar for local and overseas markets. The founders of Tomcar Australia came across the original Tomcar back in 2004. The first time they drove an early vehicle sideways across a 50 degree slope, they were hooked. Now, over ten years later, Tomcar Australia is in full production making modern vehicles in Melbourne with their manufacturing partner MTM Auto. The Tomcar Australia team has spent years taking the original, rough and ready Tomcar and turning it into a commercially viable Australian-manufactured vehicle. New engines, new wiring looms, new braking systems, new shocks, and over 180 engineering improvements to an already remarkable vehicle. The Tomcar is built to be parachuted out of a plane and survive. All its parts are easily accessible, simple to fix and handy to replace. Tomcar is Australian owned and manufactured, and intends to stay that way after Ford, Holden and Toyota depart. Learn About A lean manufacturing facility, including export business and the innovative TOMCAR production cell.

    Denso Automotive Systems Australia DENSO is a leading designer and manufacturer of advanced automotive technology, systems and components for all the world's major automakers. DENSO operates in 35 countries and regions with approximately 140,000 employees. They invest approximately 9 percent of consolidated sales in R&D activities. DENSO is globally recognised for manufacturing excellence and exceptional quality. The DENSO Automotive Systems Australia plant based in Croydon, Victoria has been using lean systems since the site was built in 1990 and has won numerous awards including Toyota Supplier of the Year 9 times. Their strong workforce locally manufactures air conditioning systems, engine cooling systems, air intake systems, fuel pump modules, washer bottles and instrument clusters as well as the sales of imported and aftermarket products. Learn About Levelling and Pull Flow Standard Work, TPM and Short Lead Times Developing an improvement culture Strong visual systems


     The host company reserves the right to decline attendees.

     Positions are limited to 15 participants per tour. Registrations will be accepted on a first-come first-served basis.

     Maximum two people per company, additions will be added to a waitlist.

     Cancellations can be made up to four weeks before the event. Substitutions may be made up to one week before the event.

     This event may be cancelled by AME for any reason. AME is not r


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