What started as a small idea from MASPRO to change up its workshops has evolved into something far more significant.
MASPRO’s past year has been one of transformation.
An initiative that began as a series of workshop modifications has grown into a company-wide shift in how production is planned, executed, and scaled for the future.
The result has been leaner operations, smarter use of technology and a production environment designed to meet the long-term needs of the mining industry.
Production efficiency has always been central to MASPRO’s operations, but the company recently took a step back to ask a bigger question: where do we want to be in 10 years?
That long-term perspective shaped a new workshop layout designed not just for today’s workloads but for future growth.
By grouping related processes together and aligning workstations with production flow, MASPRO has reduced unnecessary movement across the shop floor.
“We took the approach of saying, where do we want to see ourselves within the next 10 years, and then worked backwards,” MASPRO production manager Arnold Small told Australian Mining.
“It was about improving quality, efficiency, and the flow of material.”
These changes have also given MASPRO the ability and flexibility to adapt quickly to client needs.
“We can respond to long production runs or urgent requirements,” Small said. “The shop floor can be adjusted to suit the current need.”
A standout investment has been the installation of a new overhead crane above MASPRO’s Hercules machining centre.
Hercules, the Hartford HSA4210 machining centre, stands as a beacon of precision and efficiency in computer numerical control (CNC) technology. Crafted with accuracy and care, Hercules boasts exceptional rigidity and stability, ensuring consistent and precise machining results even in the most demanding production environments.
With its formidable spindle power and advanced features, Hercules aims to set the standard for high-speed machining operations.
Designed for the company’s largest components, the two-tonne system has doubled throughput by cutting handling time and reducing manual lifting.
MASPRO director of operations Jason Kennard said the crane also delivers flow-on benefits.
“It’s not just about moving heavy parts more safely,” he told Australian Mining. “It allows us to keep scheduling consistent and reduce delays between stages. That reliability is crucial for our clients.”
Alongside physical upgrades, MASPRO has rolled out a suite of continuous improvement initiatives. Offline programming now allows machining programs and tool set-ups to be prepared a week in advance, removing downtime and ensuring operators can focus on precision work.
Four machining centres are being integrated with robotic arms to create an automated work cell that improves consistency and scalability.
At the Wetherill Park facility in NSW, machining space has been consolidated to free up floor area for welding and assembly as demand grows.
Robotic welding is advancing quickly, with MASPRO’s welding arm, Bertha, now tackling complex jobs with enhanced precession, efficiency and quality.
“Realigning the shop floor makes operations department-orientated,” Small said. “With less staff movement and better process visibility, we’ve reduced travel time and improved consistency.”
For MASPRO’s mining clients, the benefits are immediate and tangible. Faster turnaround times and reduced downtime help keep equipment running, but the company is also using its agility to deliver tailored solutions.
There was a recent case where MASPRO redesigned a component after repeated failures in an existing part.
“We had a client with issues around a cradle pin working loose,” Kennard said. “We added a safety lip so that even if it came loose, it couldn’t fall out.
“That kind of improvement not only reduces risk but saves clients money over time.”
In another example, urgent requests that would normally take 20–30 days were completed in just 10 days thanks to the streamlined layout and offline programming.
This customer-first mindset reflects MASPRO’s broader evolution.
“We started out making components cheaper than OEM (original equipment manufacturer) parts,” Kennard said. “But we’ve evolved to ask, ‘How can we make them better?’ Whether it’s a change of material, a new welding sequence, or a design tweak, we’re always looking to extend part life and improve safety.”
That philosophy has cemented MASPRO’s reputation as more than a supplier; it’s now a partner helping miners solve problems and improve equipment performance.
The combined impact of these changes has been clear. Lead times are down, production stoppages are fewer, and throughput has increased. But MASPRO views this year’s gains as only the first phase of a much larger journey, with every initiative implemented with scalability in mind.
Whether it’s the crane system, the rearranged floor plan, or robotic integration, each improvement builds towards a long-term growth strategy.
At MASPRO, leadership is about keeping that balance between immediate needs and future direction.
“We plan carefully so urgent jobs don’t disrupt flow,” Kennard said. “It’s about flexibility today and sustainability tomorrow.”
Ultimately, MASPRO’s investments reflect its role in supporting Australian miners. Reliability, turnaround time and quality are more than internal metrics; they are crucial in an industry where downtime can be very costly.
“By reorganising our workshops, introducing automation, and focusing on quality, we’re ensuring MASPRO is equipped not just for today’s challenges but for the next decade of mining,” Small said.
With a culture of continuous improvement, MASPRO is proving that smart manufacturing isn’t about working harder; it’s about working smarter and building a foundation strong enough to carry the industry forward.
This article appeared in the October edition of Australian Mining magazine.
