Operations
Circulating Coin Production
During the year the production of circulating coin totalled 526 million which was a reduction of 106 million from the previous year. The RBA ordered 391 million coins; a decrease of 28 per cent on the previous year. During the year there were over 300 million coins produced and held to cover a period of 6 months for shutdown of production to take account of the refurbishment program.
Following a detailed study in late 2005 to determine reasons for poor press performance a review was undertaken of the Mint’s maintenance program. As a result of implementing recommendations from the review there was a marked increase in machine efficiency during the year, and by year’s end all presses were operating at peak efficiency. Press related problems due to a lack of spare parts, skilled tradespeople and poor maintenance regimes were also addressed during the year and contributed to the improved performance.
A 5S workplace (tidiness and orderliness) program was introduced to the circulating coin production area, which resulted in a marked improvement in workplace presentation and has initiated a shift toward a more modern workplace culture.
Numismatic Coin Production
A feature of the year was the higher level of training activities applied to the tasks of die setting and proof coining. More rigorous training of press operators in a one-on-one instructional situation has led to improved production efficiency with an increase in quality standards.
During the year a detailed survey of the proof coining presses was conducted by a specialist firm in the construction and maintenance of mechanical presses. The results indicated that the condition of the equipment was generally good; however, the report highlighted a number of refurbishment and maintenance issues which will be carried out during the period of production shutdown.
Planning
The planning section of the Mint was restructured to become a part of the production department, and as a consequence there is now only one interface between the marketing and production sections, resulting in a much higher level of cooperation and understanding between these two teams. There is now a broader perspective in planning production activities, with a greater focus on reducing costs while meeting market demands.
The Mint's decision to decrease the number of contract staff has meant that planning has necessarily taken a longer-term view to ensure that workforce labour is efficiently utilised.
Production Services
Newly created during the first quarter of the financial year, Production Services now incorporates the functions of Design and Engraving, Tool room, Metrology, and Research and Development (R&D). These areas provide coin designs, master dies, tooling and coin dies for coining presses and engineering services to the Production Branch.
The Mint refurbishment has increased the demand on each section to produce their services in a shorter time period as a consequence of many product orders being brought forward to meet the shutdowns in circulating and proof coining sections.
The Design and Engraving section was joined in early 2007 by a new coin designer (under tutelage) to meet succession planning requirements, and to augment the skills of the two existing staff during the demanding refurbishment period.
New design work on small gold coins was completed to expand the coin range to include $10 and $25 gold coins, equivalent in size to the previous 1 cent and 2 cent coins. The 2007 $25 Kangaroo at Sunset in particular was a noteworthy design with the 1000 mintage sold within days of release.
As a result of increased demand for master tools the workload for the two Computer Numerically Controlled (CNC) engraving machines was increased during the year. An additional focus on staff training in 2007-08 will help the Mint cope with this extra demand.
The Tool room teams have made 5,500 coining dies for circulating and proof coin production and quantities of press parts, including 11,000 press fingers for feeding coin blanks into the circulating coin presses, as well as providing Tool room services to internal clients.
Several opportunities for staff learning and development during the year included the introduction of the 5S Program, visits to factories and trade shows, demonstrations of Tool room processes for students, business visitors and customers and the education of Fitting and Machining apprentices.
The R&D section contributed to the production of Mint products in significant ways. During the year the Tool room collaborated on a major part redesign and remanufacture project. The project is being expanded to include more press parts. The strategy offers a reduction in the cost of replacement parts, timely repair of presses, improved press availability for coin making and an extension in useful life. The strategy will be expanded to include proof coin presses.
The laser frosting machine successfully completed trials for coinage dies and has now progressed to the production of specialised dies for proof coin manufacture. The modifications developed during the trial period were adopted by the laser machine manufacturer and were included in a demonstration at the World Money Fair in Berlin in February 2007.
The Mint’s coin alignment checking machine engineered by R&D staff passed its trial period. A production version is being constructed and will enter production in late 2007. This machine has generated great interest within the wider minting community.
The Metrology laboratory assumed a greater role in the measurement of master tools and the testing of production coins for improved coinability with the aim of reducing coin costs with improved tooling and die life.
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