CASE STUDY | Fletcher Steel
Fletcher Steel is New Zealand’s leading importer, distributor and processor of steel. They provide a wide range of steel products and solutions to multiple markets, and have a strong legacy of innovation, quality, and dedication to sustainability and efficiency.
THE CHALLENGE
Fletcher Steel has multiple sites around the country, supported by a lean and highly efficient Engineering Projects team. The complexity and scale of their projects demands a high level of engineering expertise and project engineering capability.
To manage their periods of high workload, Fletcher steel needed a resource solution that would enable them to maintain their high standards of quality, efficiency, and safety, while delivering their projects within strict timeframes and budgets.
THE SOLUTION
Caliber’s seconded business model is an ideal solution for Fletcher Steel.
Having one of our mechanical engineers join their Engineering Projects team when required means that Fletcher Steel can use our engineers’ skills wherever they need them most. From feasibility to install, and everything in between, our engineers can slot in and do what is required to get projects completed on time, in budget, and to the desired quality. The fact that our engineers all have a strong design background, a capacity that Fletcher Steel don’t have in-house, is a big plus.
Having completed a few projects together now, Fletcher Steel know that they can count on Caliber to provide quality engineering resource when they need it, and we have a good understanding of their operational needs and internal systems.
“Gene made my life easier by being reliable, and by being a very direct communicator. I liked that he highlighted the main points of a conversation right from the start; Gene doesn’t waffle which is great when we’re working on tight timelines. Gene got up to speed quickly in terms of understanding of how we operate what needs to be done in a Project Engineering role at Fletchers. He consistently interacted well with contractors and stakeholders.”
PROJECTS & TASKS
Stapler machine relocation
Fletcher Steel identified that the existing configuration of their machinery did not meet the ASNZ-4024 standard, posing a potential safety risk. To urgently address this issue, they needed a business case and feasibility study to be conducted to secure Capex approval. They didn’t have a capacity within their own team to do this, so asked Caliber to help move the project forward. After careful consideration, the project charter was developed, and Capex was granted. Caliber took on the responsibility of project management, coordinating with various contractors and overseeing site work. As a result of this project, the safety risk was successfully mitigated, ensuring compliance with the ASNZ-4024 standard.
Recoiler Design & Relocation Project
Led the design and fabrication of new lifting equipment to increase packaging speeds of steel wire-coils for heavy industry. Managed the full project lifecycle from initiation to closing, including project budget creation, design engineering, sheet metal fabrication, assembly, and coordination.
Redbud feasibility study
One of Fletchers existing machines had an outdated obsolete HMI and PLC. They had an old quote to upgrade or replace the components, however it was out of date so they tasked Caliber with doing a feasibility study. The Caliber engineer gathered information, liasied with the manufacturer, and presented Fletchers management with a project charter document. This outlined the business case, and estimated timeline and project cost. On review, it was decided that it was too expensive to replace or upgrade the machine. A second option was presented, to re-code the machine. Caliber defined the scope of work to be done and leasing with the potential programs to be able to re-code the existing machine to get estimated quotes for the machine.
Durmech Project Feasibility Study
Led planning for a complex machine upgrade in the heavy industry sector to package 4T steel coils for the Easysteel Division. Evaluated feasibility, scope, and cost of changes, seeking advice from mechanical workers, hydraulicsexperts, builders, electricians, conveyor equipment manufacturers, safety engineers, and installers.Responsibilities included project management, site measurements, 3D modelling of proposed layout,and creating a half-million-dollar project proposal.
Robot seam welder feasibility study
Fletchers wished to improve the capacity, finish quality, and safety of an existing welding process. They had a potential supplier, but needed a feasibility study done to prove the proposed line would be fit for purpose. Caliber was responsible for creating a new factory layout, creating a project charter document, and liaising with the supplier and contractors. We also developed project plans, project timelines, time study, and cost of running the current system vs the proposed system. This got the project to the point of being ready for CAPEX approval.