90 new workstations, no lost production time.
Tuff Group makes bespoke 4WD and truck accessories from manufacturing sites in Toowoomba and Brisbane. We replaced 90 ageing workstations across both locations - office desks and factory-floor stations alike - and staged the rollout so the production line kept running through it.
A fleet getting slower while the factory kept running.
Tuff Group's workstations had been getting slower for years. Devices were out of warranty, replacement parts were getting harder to source, and the productivity cost was building across 150 staff. The obvious answer was to replace them all at once, except a manufacturing operation can't stop for an IT rollout.
Putting a figure on what the slowdown was costing.
Our team had been seeing the symptoms on site visits, and we brought Tuff Group's management a costed comparison before recommending the work.
Slow workstations cost roughly 13 minutes per staff member per day - about 5.5 days a year. Across 150 staff, that's measurable hours that don't show up on any single invoice, and the total adds up faster than the cost of new hardware. Once the cost was in numbers everyone agreed on, the scheduling was the easier part.
No experiments on the factory floor.
The workstations we recommended were models we'd already deployed at similar manufacturing clients.
We'd seen them sit through factory-floor heat, dust, and rough handling at other sites, and we knew which spec held up under the workload Tuff would put through them. The quote was an option list against known-good kit, not an evaluation.
Sized to what the line could absorb.
We took delivery of all 90 units up front and stored them on site, then deployed them in segments that fit Tuff's production schedule and Christmas calendar.
Each wave was sized to what could be cut over without affecting the line, and the order was set by Tuff Group's own priorities. The factory kept running through the entire rollout, and the last wave landed before the Christmas slowdown.
90 in, and not a shift lost.
All 90 workstations are in, the productivity drag has lifted, and Tuff Group's factory kept running for every shift through the rollout.
Hardware running on borrowed time?
A refresh that fits around the line.