HOW STEVENSON ENGINEERING MADE A DIFFERENCE

OUR EXTENSIVE FACILITIES AND SKILLS

We are one of the few engineering workshops in New Zealand that has generators capable of converting power from 400 to 1000 volts in order to test drive these machines, and our ability to provide diesel engine compliance testing and emission documentation in-house means we save our customer time and money.

Our East Tamaki workshop is also large enough to accommodate these huge machines, and we have a wide range of highly skilled tradesmen capable of carrying out the job from start to finish, all under one roof.

We currently have fitter welders, diesel mechanics, line borers and machinists working on rebuilds or repairs for different items of underground mining equipment for Solid Energy, including a Joy continuous miner and Stamler coal processor, as well as loaders and shuttle cars.

 

THE RIGHT PROCEDURES IN PLACE

Because underground mining equipment has to adhere to stringent NSW mining standards, one of the strictest in the world, it’s important that we closely follow all procedures and supply detailed and exact documentation when working on these machines.

Full compliance and documentation is provided by us to Solid Energy at every stage, and we have weekly meetings with one of their engineers to report on our progress, with photographs provided.

Once each rebuild is complete, we provide Solid Energy with a comprehensive manual that includes repair instructions, product specifications and full documentation and compliance certifications on all product and materials.

 

WE GO ABOVE AND BEYOND

We’re not satisfied with just fixing what’s required and doing the bare minimum. Since undertaking the work for Solid Energy, we have taken their concerns and ideas on board to achieve the best outcome wherever and whenever we can.

This includes rebuilding equipment as smaller units to make it easier for them to pull apart for quicker service, developing braking systems and scrubber units to filter the air, as well as various upgrades to improve efficiency.

“We’ve worked closely with Solid Energy to really understand their objectives, and that’s our point of difference. In the end, we’ve come up with a better product, and it’s all due to the teamwork on both sides.” – David Pinfold, workshop supervisor.

 

QUALITY ACCREDITATIONS: ISO 9001 AND ENVIRO-MARK DIAMOND

On having ISO 9001

As well as adhering to the stringent mining standards, we also follow the procedures set by ISO to ensure we deliver a quality service and a high standard of work every time.

Everything has to be done to a specification and recorded, so there’s a clear paper trail should this be needed at a later date.

It’s all about reassuring Solid Energy that the work we’re doing for them is done correctly and to a standard they can be satisfied with.

 

ON ACHIEVING ENVIRO-MARK®NZ DIAMOND CERTIFICATION

This certification helps support Solid Energy’s sustainability aims, and we work hard to ensure that all oils, fluids and waste removed from their equipment is disposed of responsibly and recycled whenever possible. Consideration to noise and dust control are also applied to the machines to create a safer working environment for the operator.

THE RESULT

So far, we have rebuilt fifteen miners for Solid Energy, including Stamler, Joy and Eimco machines. We work on a four-year cycle for each rebuild and a two-year cycle for mid-life rebuilds, and most of this work is carried out at our East Tamaki workshop. In addition to that, we also provide them with a general maintenance programme, as well as carrying out minor repairs on satellite operation sites.

 

THE WORK

Holcim NZ needed someone to service, maintain and rebuild their fleet of machines at the Holcim Bombay quarry. This included dump trucks, wheel loaders, excavators, pumps and more. Since winning the contract, we have been involved in a range of work, from engine rebuilds and transmission overhauls, to breakdown call-outs, repairing ground engaging tools (buckets, blades, trays) and preventative maintenance work.

As part of our service, we also provide Holcim NZ with a dedicated field service team that is available 24/7 to respond to any callouts, breakdowns and urgent repairs if needed.

HOW STEVENSON ENGINEERING MADE A DIFFERENCE

ON TIME, ON BUDGET

Our ability to deliver on time and at the right price is another important aspect of our success with Holcim NZ. It’s all about getting the machinery up and going as fast as we possibly can, and our response time, after-hours service and wide range of skill sets contribute to that. We also endeavor to work around their plant schedules, so that it’s operating at 100% all the time.

“Holcim NZ had to get their trucks rebuilt, and they wanted service work done on the engines and transmissions over Christmas. So we put in the hours, worked through the Christmas break and we met the targets. The trucks were delivered back on time, ready for work the following year.” – Ward O’Donnell, engine shop supervisor.

OUR PLACE, OR THEIRS

We have a field service team of 5 who are always on-call and available to head out to Holcim NZ’s premises when needed. Most of the equipment is serviced on-site, with the exception of bigger projects such as dump truck and component rebuilds, or truck deck relinings, which are brought back to our East Tamaki workshop. That’s because our workshop is a one-stop-shop where our staff have the skills and knowledge, backed up by facilities like the weld shop, machine shop, engine shop, hydraulics and more, which makes working on large scale projects quicker and more cost-effective.

REGULAR CONTACT

Gary Richmond, Stevenson Engineering’s account manager for Holcim NZ, believes that good communication is key, which is why he keeps in regular contact with the quarry manager and maintenance manager.

Monthly meetings are held every first Tuesday of each month to discuss plant maintenance and maintenance planning schedules. Gary also gets in touch every Monday morning to see if they have any specific requirements for the week ahead, and to check if the jobs completed the previous week met their expectations.

Steve Sagar, a field service mechanic says, “The team at Holcim NZ like knowing what’s going on, so we keep them in the loop and communicate regularly.”

 

QUALITY ACCREDITATIONS: ISO 9001 AND ENVIRO-MARK®NZ DIAMOND

On having ISO 9001

This is where the ISO 9001 certification comes in. Everything has to be done to a specification and recorded, so there’s an audit trail should anything ever go wrong.

It’s about the assurance that the work we’re doing for Holcim is done in the correct manner, to the right level. We believe a customer needs to have confidence in our ability to deliver a high standard of work, and that we have the procedures in place to monitor that work.

ON ACHIEVING ENVIRO-MARK®NZ DIAMOND CERTIFICATION

Enviro-Mark®NZ Diamond certification gives Holcim NZ the knowledge that all work done by us is performed in a safe and environmentally responsible way. Holcim NZ aims to be the national segment leader on health and safety in their industry, so we do all we can to help them achieve that goal, such as taking care to avoid spills and hazards and recycling everything we can. As part of Stevenson Engineering’s commitment to the environment and health and safety, a designated battery disposal shed has been built on our workshop’s premises, and the engine oil collected at Holcim NZ’s site is brought back to our premises so we can dispose of it properly.

 

THE RESULT

After four years and an average of 2,200 hours per unit per annum, it’s fair to say Holcim is a satisfied customer.

THE WORK

We were contracted to provide light to medium-sized equipment and vehicle maintenance for Downer. This equipment and machinery is primarily used for local body maintenance contracts, which include park maintenance and groundcare work for reserves and sports fields. Since taking over the workshop, we have serviced, repaired and maintained over 750 items of machinery, ranging from chainsaws, leafblowers and lawnmowers, to earthmoving equipment, coring machines, grass sowing machines and more.

 

HOW STEVENSON ENGINEERING MADE A DIFFERENCE

HAVING A PERFORMANCE-BASED CONTRACT

Because Downer is measured on very stringent key performance indicators (KPIs) by the likes of Auckland City and Manukau City Council, there is no room for error. So we put a performance-based contract in place, to show Downer that they have our support, and that we are extremely committed to delivering a quality service, each and every time.

The KPIs set by Downer measure everything we do, from our response times, quality of work and customer service. Quarterly meetings are held to review and assess the work.

OUR ONE-STOP-SHOP WORKSHOP

The wide range of facilities and skills we have at our East Tamaki workshop plays a big part in our relationship with Downer. Because we’re not a franchise-style garage, we can work on different brands and types of machinery, and we have the knowledge and experience backing us up.

This means we provide everything from auto-electrical services to welding all under one roof, saving our customer time and money so they can get their machine up and running as soon as possible.

 

QUALITY ACCREDITATIONS: ISO 9001 AND ENVIRO-MARK®NZ DIAMOND

On having ISO 9001

In addition to the stringent KPIs set by Downer, we also follow procedures set out in ISO 9001 to ensure that we deliver a quality service and a high standard of work every time.

As a large company with over 100 people working here, we believe it’s important to have the right systems in place, where we record all the work we do so the there’s accountability and a standard to work to.

ON ACHIEVING ENVIRO-MARK®NZ DIAMOND CERTIFICATION

As we look after Downer’s groundcare and park maintenance equipment, it makes sense that we do it in an environmentally responsible way. This certification demonstrates that we are proactive in doing so, and that any work we do for our customers is done with the idea of minimising and preventing environmental damage on their site.

 

THE RESULT

In the two years we’ve worked for Downer, we have exceeded their requirement for an 85% customer satisfaction rating. We believe that we can continue to improve on that result, and our goal is to reduce Downer’s goods and services costs by no less than 10% by the 31st of December, 2010.