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Zero defects, zero delays, and zero returns… Elexon Electronics' ambitious program aligned with Primes’ quality management strategies.
We are living in a transformative era where superior quality and reliability have become non-negotiable imperatives, especially in defence. The Sovereign Guided Weapons and Explosive Ordnance Enterprise (GWEO), alongside other critical initiatives under the AUKUS agreement, are setting new benchmarks in the defence industry. Australian suppliers like Elexon Electronics are rising to the challenge, preparing to meet these heightened standards. The supply chain required for the accelerated delivery of these projects is unprecedented, demanding an extensive and unparalleled approach compared to past projects.
Quality improvement program aligned with Defence Primes Objectives
As these defence programs call for exceptional quality and precision, Elexon Electronics is stepping boldly into the future, aiming to become a leader in zero-faults, high-quality precision design and manufacturing. By embracing its newly launched Elexon2Zero program, Elexon is committed to enhancing quality, minimizing waste, and reducing costs.
This transformation is driven by the company's commitment to customer success led by their CEO, Frank Faller. "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 Frank Faller.
At the heart of this evolution is the Elexon2Zero continuous improvement program, a cornerstone in the company's ambitious journey towards ELEXON 2.0. This initiative is set to redefine manufacturing standards in Australia, aligning with the broader goal of achieving a net-zero future.
The Ambitious Vision of Elexon2Zero
Elexon Electronics seized this opportunity to revolutionise their approach to design, manufacturing, and customer support as a reaction to their recovery after last year’s fire incident in their smart factory.
"We rebuilt and upgraded our manufacturing capabilities," explained Frank Faller. "We have new equipment, a facility twice the size of our previous one, and we’ve been producing more products than ever. We’ve also been hiring a range of staff, from assembly workers to engineering and technical personnel. We knew it was now or never that we have a chance to redevelop our processes and bring better outcomes for our customers. That’s how Elexon2Zero came about, and it is very exciting to be part of it."
Innovative Manufacturing Set-Up
Elexon's approach to achieving its zero-faults goals involves substantial upgrades to its manufacturing processes.
We have introduced additional inspection equipment, including advanced solder paste inspection (SPI)," detailed Frank Faller. "Our upgraded pick-and-place machines are now more accurate and faster, we’ve integrated 3D automatic optical inspection (AOI), 3D CT X-ray equipment, and Flying Probe testers into our automated line. With these advancements, Elexon has established a one of a kind electronics manufacturing facility with true Industry 4.0 capabilities, allowing for precise adjustments to solder paste and enhanced overall quality
To adhere with defence expectations, Elexon has added a second production line designed for prototyping and small runs. "This line uses compatible equipment, making it easier to introduce new products to the manufacturing process. As volumes increase, we can seamlessly transition products to the main production line," Frank explained his plan. These improvements are critical steps towards achieving the Elexon2Zero goals, allowing for better data collection and targeted actions to reach quality and sustainability objectives.
Industry Reaction to Elexon2Zero
Elexon's efforts have not gone unnoticed. "Our larger corporate and defence clients are especially receptive to the concept of zero defects, zero delays, and zero returns. It aligns with their key metrics of improving outgoing quality," said John White, Elexon Electronics’ Business Development Manager. "The Elexon2Zero initiative aims to enhance on-time delivery, improve product quality, and ultimately reduce costs. By improving the quality of the finished product, we also lower the overall cost of ownership, which is a major advantage for our customers."
Elexon2Zero also offers environmental and sustainability benefits. "Achieving these goals helps us reduce waste, which, while responsibly managed, still has an environmental impact. By minimizing waste, we not only benefit the environment but also reduce associated costs," John White added.
Embracing Industry 4.0
The upgrades at Elexon have significantly enhanced complete traceability of the manufacturing processes, aligning with Industry 4.0 principles.
"Materials are now stored in automated robotic towers or control towers. These systems manage the materials needed for each job, automatically providing them to the machines and calling for additional supplies as needed. This creates immediate feedback between machines and ensures a continuous, efficient operation without manual intervention," explains John.
Methodologies for Success
Elexon employs several methodologies to drive the success of the Elexon2Zero program. "Six Sigma helps us identify and address process variations by creating measurement systems to achieve our targets," White said. "Lean methodologies focus on optimizing our processes by eliminating waste and enhancing efficiency. Through Lean, we streamline workflows, reduce unnecessary steps, and ensure that every part of the process adds value, contributing to the overall success of the Elexon2Zero initiative."
Agile practices are applied across the business, particularly in project management. "Agile allows us to adapt quickly to changes and manage projects more efficiently. By using Agile, we ensure that our initiatives are flexible, responsive, and aligned with our goals, which supports the dynamic nature of the Elexon2Zero program," White emphasized.
Quality and Metrics
"In electronics manufacturing, having really great control over the right amount of solder paste being put on PCBs is the root of the quality problem. If you get that right, then that brings good quality into the day," says Frank Faller who’s devoted his career to electronics manufacturing and process development.
Elexon’s cutting-edge manufacturing equipment, including a solder jet printer and vapor phase reflow oven, ensures superior quality. "We're always looking for incremental improvements through this new Elexon2Zero program," White said. "The great company culture within the business means that we attract employees who stay for the long term, much longer than the average tenure rate you see today. The fact that we've designed the product and manufactured it for the customer is something that people take great pride in."
"We have implemented rigorous quality control systems. At this stage, we are developing a new set of metrics and measurements specifically targeted around identified issues that we need to address. They are risk assessment-based," explained Frank. “This is a complex project involving many parts of the production process. We are not expecting to see more significant results for about six months or so; however, we are already seeing some early positive changes."
Expanding Global Reach
Focusing on participation in the current strategically important defence projects, Elexon aims to play a crucial role in programs related to guided weapons, autonomous systems, and projects under the AUKUS alliance.
As Elexon Electronics continues to evolve, their commitment to excellence and customer satisfaction remains at the forefront, driving the growth of Australia's sovereign manufacturing capability.
Meet Elexon at Land Forces
Elexon Electronics is a key partner of the Micro-Prime group of defence suppliers, co-exhibiting at the Land Forces International Land Defence Exposition from 11-13 September at the Melbourne Convention Centre.
Led by Citadel Secure, the Micro-Prime consortium offers comprehensive services across the product delivery spectrum, from supply chain management and R&D to manufacturing and sustainment. This collaboration helps harmonise Australian industry capabilities, establish partnerships with AUKUS stakeholders, and provide the Army with innovative solutions.
Elexon team will showcase their state-of-the-art electronics manufacturing facility, including Industry 4.0 capabilities, and present the transformative Elexon2Zero program.
Meet Frank Faller, our CEO, John White, Business Development Manager and Sandra Simpson Elexon’s Marketing and Strategic Development Manager at the Micro-Prime Stand C045!
