When McConnell Seats first swapped scissors for automated cutters, the company wasn’t just upgrading equipment but laying the foundation for a strong Victorian manufacturing partnership.
Two decades later, McConnell and Pathfinder Cutting Technology are still moving together, adapting to an industry where speed, accuracy, and local capability are more critical than ever.
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“The relationship began back in 2005, when Pathfinder’s founder John Hollo dropped into McConnell Seats and introduced himself to Dennis McConnell and Alan Smith,” Pathfinder sales manager Wayne Walker told ABC.
“At that time, McConnell’s upholstery cutting process was still largely analogue, using hand-cut templates and scissors.
“Denis and Alan quickly recognised that investing in digital technology was essential for the future, and within just a few months, Pathfinder installed a CAD system and a K-Series CNC cutting machine.”
In the twenty years since, that decision has paid dividends. Thousands of buses and coaches across Australia have been fitted with McConnell’s expertly crafted seating, with fabrics precision-cut on Pathfinder’s technology.
But technology, like the industry itself, never stands still.
Now, McConnell Seats is ushering in a new era with the installation of the latest Pathfinder M-Series system, complete with the advanced FabricPro automatic material spreader.
“The new system is a major leap forward,” McConnell Australia general manager James Lowe told ABC.
“It’s faster, it’s smarter, and it’s more sustainable. It allows us to maximise material efficiency, reduce waste, and keep production moving without relying heavily on skilled manual labour, which is becoming harder to find.”
The M-Series was designed around a few critical principles: ease of use, minimal maintenance, productive engineering, and safety. This new technology not only improves cutting precision and production speed but also helps digitise workflows, providing McConnell with better data for planning, scheduling, and training.
“In today’s world, you can’t afford to stand still. You either innovate or you get left behind,” Walker says.
“No one’s rushing back to the horse and cart anytime soon, and the same is true for manufacturing methods.”
The McConnell/Pathfinder partnership is a shining example of the power of local collaboration, something that’s vital for Victoria’s manufacturing sector.
“Strong local partnerships are the backbone of a resilient manufacturing economy,” Lowe says.
“By sourcing materials, technology, and expertise locally, you’re not just creating jobs, you’re strengthening communities and building capabilities that are essential for long-term prosperity.”
This local-first philosophy has tangible benefits. Pathfinder manufactures its machines and software right here in Victoria, working with over 200 local suppliers. McConnell, in turn, benefits from immediate access to service, support, and innovation, a stark contrast to the long lead times and uncertainties that can plague companies reliant on overseas supply chains.
“It’s not just about dollars and cents but about building an industry that can sustain itself and compete on the world stage,” Lowe says.
“Around 80 per cent of our supply chain is based in Victoria. It is critical for us, and the people we work with, that those relationships remain.”
Volgren are a key customer of McConnell’s, forming part of that critical supply chain. Lowe says the flow on effect from the bus body manufacturer and other OEM’s is felt down the line.
“If the volume of orders is reduced through Volgren, it will impact McConnell and numerous other businesses through the rest of the chain,” he says.
“That is why it’s essential to keep the Victorian bus and coach industry alive and thriving.”
After decades of offshoring and underinvestment, Walker says it’s clear the industry needs to maintain strong sovereign manufacturing capabilities, not just for economic prosperity, but for national resilience.
“We’re proud that our machines, built right here in Melbourne, are running in some of the world’s most advanced manufacturing facilities,” Walker says.
“It’s proof that Australia still makes world-class products. You just have to know where to look.
“Whenever possible, we believe it’s better to partner locally. If more companies understood the full economic and social impact of keeping supply chains and money local, we’d have even stronger communities and industries.”
Alongside its technology upgrades, McConnell Seats is also leading the way in adapting to new Australian safety regulations. McConnell are updating its seating offerings to comply with the updated seat belt Australian Design Rules (ADRs).
In new buses and coaches, visual and audible alerts will be introduced to encourage seatbelt usage. A label must also be sewn on each seat back and modesty panel reading “Fasten seat belts while seated”.
“Working with operators allows us to combine practical fleet experience with our manufacturing expertise,” Lowe says.
“We’re designing seating solutions that are safer, more durable, and aligned with the future needs of operators.”
This new project not only strengthens McConnell’s product offering but also reinforces its commitment to supporting the evolving needs of the Australian bus and coach industry.
As standards continue to rise, McConnell is positioning itself as a key partner for operators who demand quality and local manufacturing support.