🌅 Industry 4.0 in Australian Caravan Manufacturing
Practical wins, not buzzwords
The Digital Thread
Common Pain Points
📦 Parts Arrive Late
Build stops, schedule disrupted, delivery dates missed
🔄 Option Changes
Not communicated → rework + defects + cost overruns
❓ Patchy QC Evidence
Arguments with dealers & customers, unclear accountability
🔁 Repeat Warranty Issues
“We’ve seen this before” but nothing changes
4 Key Changes on Factory Floors
🎯 Targeted Automation
Barcode scanning, pick/pack verification, stage gate checklists, time capture at bottlenecks
👁️ Real-Time Visibility
WIP location, downtime reasons, rework capture, stock accuracy
🔮 Process Digital Twin
Model production stages, test capacity changes, realistic forecasting, traceability
🤝 Ecosystem Integration
Supplier ETAs, dealer comms, warranty feedback linked to build stages
Impact on Key Metrics
Your “Start Here” Roadmap
Stabilise Workflows
Clear stage gates, standard checklists at key points (chassis → frame → fitout → electrical → plumbing → QC)
Make WIP Visible
Where every van is, what’s blocked, real-time status tracking
Capture Rework Properly
Reasons, time, cost, recurrence patterns — turn pain into data
Connect Purchasing to Production
POs + ETAs mapped to the schedule, see shortages before they stop the line
Add Targeted Automation
Scan-to-issue, pick verification, QC evidence capture where it removes friction
KPIs That Actually Matter
On-Time Stage Completion %
Per stage: chassis / frame / fitout / QC
Days Blocked Per Van
Top 3 reasons: parts, rework, labour, drawings
First-Pass Quality Rate
Passes QC without rework
Rework Hours Per Van
And top causes tracked
Warranty Claims Per 100 Vans
By category + linked to build stage / supplier
Biggest Implementation Challenges
The Bottom Line
Industry 4.0 succeeds when the operational basics are nailed — the digital thread between order → production → purchasing → quality → delivery → warranty
From “we’re always busy” to “we’re actually improving”
