Elexon Electronics sets sights on perfection with Elexon2Zero initiative
Brisbane-based innovation company Elexon Electronics is embarking on a transformative journey with the Elexon2Zero program. This initiative signifies a major evolution for the post-recovery era of business, introducing a world-class quality enhancement program with three ambitious goals: zero defects, zero delays, and zero returns.
Now commencing the new era internally called Elexon 2.0, the company’s enduring focus on quality and continuous improvement is taking them into the future with a state-of-the-art facility and bright outlook that align with the goals of product quality enhancement and fault reduction Elexon2Zero program. But let us take you back to the devastating event that started this journey.
Fire incident as the start of Elexon 2.0
After a devastating fire in August last year reduced their site of almost twenty years to rubble, Elexon Electronics took the opportunity to revolutionise the way they design, manufacture and support customers now and into the future.
Rising from the ashes, Elexon Electronics acquired a new facility twice as large, just 1.5km from the old site in Brendale, on Brisbane’s northside. The team, alongside industry partners and machinery suppliers like Mycronic Technologies AB, Suba Engineering and HW Technologies worked day and night, to create a new industry 4.0 facility that was up and running just four months after the fire.
Embarking on the Elexon 2.0 journey, the company is shifting its focus from recovery towards quality and continuous improvement, setting the stage for the future in alignment with the innovative Elexon2Zero program.
Smart Factory
The first piece of the Elexon2Zero puzzle is a new Industry 4.0 facility featuring the latest manufacturing equipment and technology from around the world.
The Elexon 2.0 site has become Queensland’s most advanced electronics manufacturing facility, including two surface mount technology (SMT) lines for manufacturing high-performance and reliable Printed Circuit Board Assemblies (PCBAs) mounts.
The other essential component is the Elexon team. Elexon Electronics has embraced Six Sigma, Lean, and Agile methodologies to enhance responsiveness, efficiency, and customer focus within the business. This was accompanied by a comprehensive internal restructuring of teams and processes, emphasizing ownership and empowering staff to drive independent improvement initiatives.
Zero defects, zero delays, zero returns
“We decided to take Elexon Electronics into the future as a zero-faults, high-quality precision design and manufacturing leader, always with the customer’s success in mind, offering complete peace of mind to the customer,” said Elexon Electronics CEO Frank Faller.
“Our new Elexon2Zero continuous improvement program is central in our evolution to ELEXON 2.0 as we redefine manufacturing standards in Australia, collectively striving to achieve a net-zero future.
“This zero-fault approach to manufacturing is the standard at leading automotive manufacturers and their suppliers like VW, Mercedes, Audi or Porsche, which is where my background is, so we are introducing it here in Brendale.
“This goes beyond just being the best company we can be. This is about taking Australia’s manufacturing industry to the global stage, onshoring high-mix, low-volume manufacturing for sectors like defence, mining, IoT, aerospace and communications,” he said.
As Australia pursues net zero by 2050, Elexon Electronics is acutely aware of the responsibility shared across the entire supply chain. Its systems and equipment have been integrated to ensure the highest possible quality, responsible sourcing and sustainable production.
The quality improvement and traceability initiatives were put in place by Elexon Electronics Quality Manager, Kylie Warren, who turned her sights to exploring how the manufacturer can enhance efficiency and traceability into the future.
“We were already a leading manufacturer of precision electronic components, but to stay ahead of the competition from offshore manufacturers we focused on becoming even more,” said Ms Warren.
“High-end precision manufacturing requires complex capability matrix. Our strength is in the well-balanced combination of automated processes and the work of the specialised and skilled team.”
Championing Australian manufacturing success
“By overcoming challenges of the last year, Elexon has taken its second chance seriously and solidified its position, showcasing Elexon Electronics’ potential as a leading Australian manufacturer for specialized projects.”
“Driving the success of the wider manufacturing industry is an overarching goal for Elexon Electronics, as the manufacturer remains committed to leading by example to improve Australia’s sovereign industrial capability. ”
“The ability for Australia to sustainably compete with cheaper offshore manufacturers is important because if we don’t step up to the plate now, it will hurt the entire industry in the long run,” said Mr Faller.
“We are committed to showcasing the best of Australian manufacturing, showing global players that we have one of the world’s most robust, sustainable and dependable manufacturing industries.
“Together, as an industry, we plan to take Australia’s manufacturing industry to a new level.”