Topic: Manufacturing

Company Description – Ben Hokum and Son Limited is a multi-generational, family-owned lumber manufacturer with over 100 employees at its Golden Lake facility near Killaloe. The company operates a sawmill, a dry kiln, and a lumber planing division in Pembroke, producing 40 million board feet of white and red pine lumber annually, with 15 million board feet of dried, graded lumber sold each year. 

Project Description – Through the Digital Modernization Adoption Plan (DMAP), Ben Hokum identified automated lumber grading as its primary modernization need. Currently Ben Hokum’s sawmill does not have the ability to separate grades when lumber is produced and bundled into loads of approximately 1,000 pieces of lumber. A bundle could consist of up to 7 different grades. Bundles must be graded before they go into the dry kiln and then regraded after it comes out to ensure customers receive the appropriate grade ordered, resulting in a very inefficient process.  

With DCC’s support, Ben Hokum installed an automated grading system that uses AI technology to streamline lumber production processes and enhance overall efficiency by speeding up the grading time, increasing volume, significantly reducing costs associated with duplication and manual grading and provide more consistent graded products. By adopting a modern grading system, Ben Hokum benefits from increased quality, reduced waste, real-time data insights, customized grading and scalability, leading to increased customer satisfaction.  

Project Impact & Potential Outcomes – As a result of DCC’s support, Ben Hokum & Son Limited experienced a transformative shift, marked by higher-quality lumber and increased customer satisfaction due to consistent automated grading. At least one new job was created through the need to manage the technical innovations, and 12 jobs were retained as a result of being able to efficiently process lumber in light of the deteriorating markets.  

The digital modernization successfully streamlined production, boosted capacity, and opened doors to new markets, making the company more competitive. Enhanced efficiency and reduced waste generated substantial cost savings, enabling reinvestment in modernization. Moreover, with real-time data insights, the company was able to drive better decision-making, showcasing its position as a forward-thinking leader in the lumber industry. 

Company Description – Bar None Designs Inc. operates a custom design and manufacturing facility for hospitality venues including restaurants, casinos, four and five-star hotels and private luxury homes. Its services include custom millwork, metalwork, decorative glass and furniture. Serving Boston, New York, Florida, Nevada (Las Vegas), and Wyoming (Jackson Hole), the family business has a proven track record and is well-reputed in North America for its value, service and commitment to its clients.  

Project Description– Through the Digital Modernization and Adoption Plan (DMAP), Bar None identified critical digital gaps contributing to slowed operational efficiency and growth potential. Existing platforms for design, manufacturing, inventory, and sales lacked seamless connectivity resulting in inefficient workflows and fragmented data management. Reliance on outdated technologies offered limited to no real-time data accessibility, impacting decision-making and agility adapting to changes in production requirements or customer needs.   

With DCC’s support, Bar None will upgrade and implement digital asset tracking, cloud computing, ICT, and ERP technologies to track products and collect, organize, and distribute information in real-time, achieving Industry 4.0 standards. By digitally modernizing its manufacturing plant, Bar None will streamline operations, optimize resource use, reduce waste, improve communication and foster a collaborative work environment attributing to a more competitive and productive business.  

Project Impact & Potential Outcomes – As a result of DCC’s support, Bar None has already secured new customers, generating $5 million in additional sales and hired 10 new employees to support the company’s growth.  

Through the Technology Demonstration Program (TDP), Bar None successfully implemented digital asset tracking, 3D CAD, cloud computing and ERP solutions. With these advancements, Bar None can efficiently and more precisely price jobs to maintain industry competitiveness and ensure timely completion of tender responses with shorter deadlines. Additionally, having a more reliable inventory system is ensuring project timelines are met while eliminating costs for obsolete inventories.  

Overall, digital modernization has driven business growth by expanding manufacturing capacity, improving cost efficiencies, and enabling Bar None to bid for and undertake new projects with greater precision and speed. 

Company Description – Arconas is a privately-owned manufacturer of specialized seating, power and furniture solutions for airports, transportation terminals and other public waiting areas. Arconas raises the value of public spaces by providing products that are high-design, innovative and durable that incorporate the latest in power technology. The company is dedicated to enhancing the passenger experience from arrival to departure with a suite of quality seating, power, waste, recycling, and counter solutions.  

Project Description – Through the Digital Modernization Adoption Plan (DMAP), Arconas identified its unintegrated ERP software as the primary modernization need. Multiple disconnected digital systems across departments resulted in manual effort, duplication, and errors. With DCC’s support, Arconas implemented a unified ERP system with built-in CRM and CPQ components, eliminating the need for data transfer between systems. The CPQ software enables accurate quotes for customizable products and provides clients with 2D design visuals. This modernization centralizes customer-related information, reduces manual data entry and errors, enhances customer relations, and improves overall efficiency. 

Project Impact & Potential Outcomes – With DCC’s support, Arconas has significantly improved operational efficiency, achieving a 5% increase in sales, including $40,843 in Canada and $1,079,243 internationally. The company has also secured two new customers in Canada and 10 internationally, along with creating five new full-time positions, with the potential to add three more. 

With the success of the Technology Demonstration Program (TDP), Arconas has been able to reinvest funds to further enhance its innovation. As the full benefits of the digital technology continue to be realized, Arconas projects sales to double, with an additional 8% increase in incremental sales anticipated within the next six months. 

Company Description – Amber Stairs & Railings Inc. specializes in the design, manufacture, and installation of custom stairs and railings for residential and commercial properties. Their product range spans traditional to modern stair systems, utilizing materials such as wood, metal, and glass to meet both aesthetic and functional client needs. They provide a comprehensive service that includes consultation, CAD-based design, manufacturing, and installation, ensuring a tailored fit for new constructions, renovations, or upgrades. 

Project Description – Through the Digital Modernization Adoption Plan (DMAP), Amber Stairs identified critical digital gaps caused by siloed, manual, and paper-based information exchange between the office and shop floor. These inefficiencies led to costing errors, limited communication, and resource waste. Additionally, the lack of integration among Amber’s information systems resulted in excessive administrative work and poor data organization and sharing. 

With DCC’s support, Amber Stairs implemented Digital 3D Laser Scanning and Asset Tracking technology, ERP system integration, and cloud computing. The Digital 3D Laser Scanner significantly reduces manual measurement errors for staircase installations, enhancing accuracy and lowering liability risks from design inaccuracies. Cloud computing facilitates real-time information sharing across departments, improving decision-making, productivity, and customer satisfaction. Integrating these technologies with an ERP system enables seamless real-time data flow from the shop floor through shipping, streamlining manufacturing routing, inventory management, installation processes, and overall operational efficiency. 

Project Impact & Potential Outcomes – As a result of DCC’s support, Amber Stairs has secured 14 new clients domestically and internationally, generating incremental sales of $800K in Canada and $500K abroad, while creating 4 new jobs and retaining 32 existing positions. The adoption of digital 3D laser technology is expected to distinguish Amber Stairs as a leader in producing and supplying custom stairs, setting it apart from competitors. This strategic digital transformation positions Amber Stairs & Railings Inc. at the forefront of technological innovation in the industry, promising strong returns on investment, enhanced competitive advantage, and improved customer satisfaction. 

Company Description – ABS Machining Inc. is a leading heavy equipment machining and fabrication company with a 50-year legacy of manufacturing world-class, large-scale machined parts. Operating across six facilities in Mississauga and Burlington, ABS specializes in producing assemblies for power generation, oil and gas, mining, and steel mill operations. Recognized as Ontario’s premier machining, milling, and fabrication provider for components exceeding 2 cubic meters in volume, ABS has delivered key projects, including power generation turbines for Ontario Power Generation and heavy equipment tractor assemblies for Caterpillar. Employing over 260 staff, 220 of whom are highly skilled machinists, millwrights, and fabricators, ABS is leveraging its reputation and success to drive an aggressive growth strategy, investing in modern equipment and two new factories in Southern Ontario, with further expansion planned. 

Project Description – Through the Digital Modernization and Adoption Plan (DMAP), ABS identified the need to upgrade and expand its existing ERP system to enhance efficiency and streamline operations. Currently, workflows rely on manual paperwork handled by over four personnel, limiting productivity. The existing ERP lacks the capabilities to support ABS’s evolving needs. Digitizing floor operations and upgrading the ERP will significantly boost productivity impact, enabling skilled tradespeople to focus on their core expertise. 

Project Impact & Projected Outcomes – As a result of DCC’s support, ABS Machining has successfully digitized workflows, upgraded systems, and integrated cutting-edge digital tools. This modernization has boosted labour efficiency, reallocating at least three full-time employees (FTEs) to sales operations and saving the equivalent of two FTEs in scheduling, allowing managers to focus on execution. 

As the full benefits of the shop floor digitization are realized, ABS forecasts a $2M increase in product exports and green energy projects, alongside a $6M increase in rare earth mineral mining equipment sales by 2025.