Levett Engineering increases capacity and efficiency with Makino a500Z CNC machines

Levett Engineering, a South Australian precision machining company, sought to increase capacity, reduce costs, and incorporate automation into its production of defence and aerospace components. By purchasing two additional Makino a500Z horizontal machining centres, supported by Headland Technology, Levett improved efficiency, reduced labour requirements, and maintained high-quality standards across multi-shift operations.

About Levett Engineering

Industry: Defence, Aerospace, and Military Manufacturing
Location: Lions Gate Elizabeth, South Australia
Team Size: 73+ employees
Facility Size: 2,000 m² (expanding to 6,000 m² in the former Holden factory)

Levett Engineering meets international quality standards for aerospace, defence, and commercial components and is ITAR compliant*.

Renowned for quality, integrity, and value, Levett employs highly skilled craftsmen dedicated to precision and on-time delivery. Using state-of-the-art equipment from leading suppliers, the team produces high-performance machined components.

As a leader in defence aviation, aerospace, and advanced manufacturing, Levett Engineering is helping drive South Australia’s transformation into an export-focused advanced manufacturing state. More about Levett Engineering

Challenge

Levett faced the following challenges:

• An ageing horizontal machining fleet limiting capacity.
• The need for automated solutions to enable multi-shift operation.
• Production of highly complex, precision components for defence and aerospace.
• Reducing labour costs while maintaining quality and efficiency.

The company required machines capable of high throughput, automation, and unmanned operation to meet growing demand and support future expansion.

Machinery requirements

Levett required machines that could:

• Run unmanned or minimally attended across multiple shifts.
• Increase efficiency and capacity compared with their existing fleet.
• Handle complex aerospace and defence components
• Maintain high precision and quality, reducing rejects.

The machines also needed to provide local support within a practical timeframe if required, avoiding long lead times from Europe.

Headland’s solution

Headland recommended Makino a500Z horizontal machining centres with MMC2 automation.

Key benefits observed by Levett include:

• Automated setup and largely unmanned operation, enabling three shifts per day, seven days a week.
• 92% machine efficiency, only limited when waiting for material.
• Enhanced throughput and reduced labour costs by approximately 30%.
• Improved precision and fewer rejects, meeting high aerospace and defence standards.

These machines allowed Levett to increase capacity and efficiency while providing the reliability required for complex, high-value components.

Implementation

Headland supported Levett Engineering with:

• Machine selection and advice, ensuring the Makino a500Z met production goals.
• Guidance on automation integration and setup optimisation.
• Ongoing service and proactive support for maintenance and troubleshooting.

The machines were successfully integrated into Levett’s workflow, supporting multi-shift production with minimal operator intervention.

Outcomes

• 15% more efficient than previous horizontal machining centres.
• 92% machine utilisation, only stopping when out of material.
• 30% reduction in labour costs due to automation and connectivity.
• Lower rejects and consistent high-quality output for complex parts.
• Capability for largely unmanned, multi-shift operation, increasing production capacity.

Paul Belshaw, General Manager, Levett Engineering, said:

“The Makino a500Z machines churn through the work where other equipment struggles. Labour costs are down, rejects are down, and efficiency is up. Headland’s support has been proactive and professional throughout.”

Advice for others in the industry:
Investing in the right CNC machinery allows manufacturers to adapt quickly to changing markets and maintain precision and reliability.

Looking to boost capacity, reduce costs, and maintain high-quality production?

Contact our CNC experts to explore Makino CNC solutions for complex, high-volume defence and aerospace components.