A Queensland marine infrastructure manufacturer has strengthened operational consistency and supervisor capability after enrolling its leadership team in Manufacturing Skills Queensland’s Operational Excellence Program.
Marine Structures, which delivers engineered pontoons, jetties, gangways and terminal structures for commercial, marina and public-access projects, turned to the MSQ-funded program to address growing complexity across its workshop operations.
The Australian manufacturer is known for safety and long-term performance, supported by specialist capability in welding, metal fabrication and modular construction. However, as operations expanded, the business began experiencing process variation between teams and emerging resistance to change.
MSQ’s Acting CEO Kris McCue said the program addresses a critical gap in Queensland’s manufacturing sector.
“As businesses scale and operations become more complex, the ability to lead improvement from the supervisor level becomes essential. We’re seeing manufacturers struggle not because they lack technical skill, but because they need stronger systems and leadership capability to manage growth effectively.
“MSQ’s Operational Excellence Program gives supervisors the practical tools and methodologies to drive sustainable improvement across their operations.”
Marine Structures enrolled supervisors and managers across production, WHS and workshop areas in the nationally recognised Certificate IV in Competitive Systems and Practices, delivered on-site by Leadership Management Australia.
Marine Structures’ People and Culture Manager Rob Dunbar said the business was fortunate to have such an experienced team.
“Naturally, with growth came the need for clearer systems, more consistency, and stronger alignment across the floor.”
“As businesses grow and face increasing complexity, having supervisors equipped with modern improvement methodologies becomes a genuine competitive advantage.”
Developing leaders to drive consistency
The program is delivered by Leadership Management Australia (LMA), a leader in organisational improvement.
Marine Structures has used the program as a comprehensive approach to capability building across their supervisory and management teams. Marine Structures has invited key staff across the business to participate including Production Supervisors, WHS Managers, Supervisors and 2ICs across both the welding and pontoon production areas.
Participants are progressing through the nationally recognised Certificate IV in Competitive Systems and Practices (MSS40322), with training delivered directly on-site to maximise practical application and minimise disruption to operations.
LMA’s Executive Chairman, Grant Sexton said growing manufacturing businesses could benefit from this type of accredited operational improvement training.
“Manufacturing businesses often have highly skilled technical teams, but the transition from technical expert to effective supervisor requires a different skill set.
“This program equips participants with the tools to lead process improvement, manage change, and build consistency across their teams. When supervisors are confident in these capabilities, the entire operation benefits, from productivity and quality through to workplace culture and engagement.”
The program’s implementation strategically coincided with Marine Structures’ rollout of new SAP software, enabling supervisors to establish more precise performance metrics and operational expectations supported by enhanced data analytics capabilities.
“The MSQ-funded program came at a perfect time for our business,” Rob said.
“This program has been important for Marine Structures. It’s making a tangible difference in how our supervisors approach problem-solving and process improvement.”
Training delivered on the workshop floor
The program is delivered twice a month by LMA Facilitator Graeme Barrett, combining structured learning with practical observation in live production environments.
Sessions include shop floor assessments, improvement recommendations, group discussions and assignments that connect Lean principles directly with Marine Structures’ daily operations.
Rob noted that while some Participants were engaged from the start, the shift in buy-in across the full cohort has been significant.
“The change has been phenomenal,” Rob said.
“Within the first two months, the entire group has shown a real uplift in engagement and commitment – we’re now at a stage where they’re ‘all-in’, and it’s brilliant to watch.”
LMA Executive Chairman Grant said the impact is both immediate and sustainable.
“When supervisors are given the right frameworks and support, they become genuine change agents within their businesses. We consistently see improvements in communication, problem-solving and operational consistency within the first few months, not just short-term training outcomes, but lasting capability.”
Key challenges being addressed
Marine Structures’ workforce spans two core operational areas: an aluminium and heavy engineering welding team, and a pontoon production section made up of concreters, labourers and installation crews.
As the business growth, several improvement needs have become clearer, including:
By focusing on supervisors, the business is ensuring that improvement is led from senior levels and passed down through strong agreed-upon systems and everyday behaviours.
Initial promising results
Practical improvements across the workshop have already been realised, including:
With supervisors increasingly aligned, Marine Structures is building momentum toward stronger consistency, improved efficiency and a more unified approach to change.
Building capability for the future
In an environment where safety, exactness and durability are critical, repeatable systems and confident leadership become essential as project demands grow.
Through MSQ’s Operational Excellence Program, Marine Structures is strengthening internal capability and equipping its leaders to drive continuous improvement across the business.
Looking to improve consistency, strengthen leadership capability, and lift productivity in your manufacturing business?
Contact Manufacturing Skills Queensland to learn more about the Operational Excellence Program.
About LMA
Leadership Management Australia (LMA) has been a pioneer in delivering people-centric business solutions since its inception in Australia in 1973. As a nationally recognised Registered Training Organisation (RTO), LMA has established itself as a leader in professional development and organisational improvement. Over the past five decades, LMA’s innovative learning and development process has empowered more than 150,000 participants across Australia and New Zealand, equipping them with the skills and knowledge to drive success in their respective industries.