Business Operations and Improvement
DONHAD
Administration was quietly capping output. Kaizen 5S found where, and payroll processing efficiency lifted by more than 54%.
Results at a glance
Efficiency gain, payroll division
More than 54%
Method
Kaizen 5S
The challenge
Where they were
DONHAD manufactures forged steel grinding media, engineering forgings and specialised fasteners for the mining and mineral processing industry — a business where plant performance is measured closely and improved constantly.
The constraint was not on the floor. Turnaround on routine administrative tasks was slow, the same data was being handled more than once, and the resulting drag on productivity was visible in the results without being traceable to a cause.
What we did
- Applied the Kaizen 5S methodology to DONHAD's existing administration processes
- Identified and analysed where delay and duplication were entering the process, rather than where they were being noticed
- Designed and implemented a re-engineered process that removed duplicate handling of data
- Addressed the underlying causes of delay in timecard processing, not just the symptoms
The outcome
What changed
Payroll processing efficiency improved by more than 54%. The gain came from removing duplicate data handling and fixing the root causes of timecard delay — waste that had been absorbed into "how it has always been done" and was costing real capacity in specific divisions of the business.
Measured results
- Payroll processing efficiency up more than 54%
- Duplicate handling of data removed from the administration process
- Root causes of timecard delay addressed, not just the symptoms
Related work
Kentin
5S implementation
Operations up 60%, downtime down 55%, errors down 40%, schedule adherence at 98% — from 5S, Kanban and a management team that now runs its own improvement cycle.
60%
Read the case studyWGAC
Asset and project feasibility
A $9m expansion at Ngula Jar Island, tested before a dollar was committed — and modelled so that government and private funders could both say yes.
$9m secured
Read the case studyCygnet Bay Pearls
CFO services
Senior financial leadership across ten entities, without the cost of a full-time CFO — and more than $5m a year in R&D rebates and tax offsets.
$5m+ a year
Read the case studyRecognise the problem
If this sounds like your business, the first conversation costs nothing.