When you think of a smash repair business, you might picture a single bustling workshop tucked away in a capital city. Tools clanging, spray guns hissing and a handful of skilled technicians working away on dented panels and scratched paint.
But Royans Group is no ordinary repairer.
Far from being a lone garage, Royans has expanded over the years into a seamlessly connected network of 27 workshops that employs over 630 specialised staff.
Strategically located across Australia (21 branches) and New Zealand (six branches), the sites work in harmony to keep buses and coaches moving.
- Subscribe to our free weekly newsletter to receive the latest news and classifieds from Australasia’s bus and coach industry
- Don’t miss a second and subscribe to our monthly ABC magazine
Its expansive footprint means operators can rely on the same high standards and fast turnaround, whether they’re in Sydney, Perth, Auckland or anywhere in between.
“Having one business with 21 workshops across Australia is incredibly beneficial to operators,” Royans CEO David Church told ABC.
“The customer can pull into any of our workshops and have something checked out.
“That’s the beauty of the branch network.”
Each of the Royans sites are fully equipped to handle a variety of issues, from accident repairs, body maintenance and panel damage to refinishing, chassis alignment and a wealth of other services.
“Each of our sites can handle the smash repair of buses,” Church says.
“We’ve tackled everything from minor panel damage to complete front-end removal and reinstalling new chassis frames.
“Conversions like wheelchair access or toilets – those go through Coachworks. But repairs? That’s every branch.”
Every job benefits from the company’s deep bench of experienced tradespeople, many of whom have spent decades with the business.
And it’s not just the people, it’s the gear too. The company is currently building a new purpose-built facility in Christchurch which will bring together two of its existing sites into one expansive workshop, fully fitted with drive-through and end-draft spray booths, overhead cranes and Josam chassis repair equipment capable of handling everything from light buses to heavy coaches and trailers.
“One of the biggest advantages we offer our customers is flexibility and consistency,” Church says.
“If you’re a bus operator working interstate or long distance and you’ve had repair work done at one of our locations, you can drop into any other branch in the network and we’ll take care of it. It’s one business with national reach.”
That flexibility becomes especially valuable in the event of an accident. Operators aren’t limited to one familiar workshop, with Royans actively presenting the best possible options, often helping customers cut down wait times significantly.
“For instance, if an accident happens halfway between two of our sites, we might say, ‘you can go south to your usual branch, or go north and save two weeks on repair time’,” Church says.
“It’s up to the customer, but we always give them the best available option.”
With such a large geographic footprint, maintaining quality and consistency is no small feat, with the company placing enormous emphasis on training and internal collaboration.
“There’s constant training across the business, in safety, processes and in new vehicle technologies,” Church says.
“If one branch comes across a new type of repair, they’ll reach out to others who may have done it before. That kind of communication is embedded into our culture.”
This is especially critical as electric buses become a growing part of the industry. Royans is actively working with OEMs and other training providers to stay ahead of the curve, ensuring its technicians are upskilled to handle new technologies as they enter operator’s fleets.
One of the new ways the smash repair company is ensuring this knowledge is with the launch of its Apprentice Academy in 2024.
Now in its second year, the program brings together apprentices from across Australia and New Zealand for an immersive introduction to the business, offering more than just technical training.
“It’s about showing them who we are, what we do and what kind of future they can have here. We want them to know there are real career paths beyond the trade,” Church says.
The academy rotates locations, with last year’s held in Victoria’s Yarra Valley and this year’s in Eastern Creek, NSW.
Royans also offers staff relocation opportunities across its sites, both domestically and internationally, preserving valuable experience within the business while giving individuals room to grow.
“We understand that sometimes there are personal reasons for needing to relocate, and we always strive to give our staff the opportunity to move to another branch, so we don’t lose their experience,” Church says.
“Some may just want a fresh start, or to try something new, and we will accommodate that.”
Beyond internal development, Royans is also working to raise the profile of the broader transport repair industry.
At the recent Brisbane Truck Show, Royans hosted a three-day event at The Depot, welcoming school students and introducing them to career opportunities in heavy vehicle repairs to play its part in building the next generation of industry talent.
“We’re doing as many things as possible to try and educate and get more people involved,” he says.
What truly distinguishes Royans in the eyes of customers is its deep understanding of transport operations and the pressure to keep vehicles moving.
“Turnaround time is critical. We know our customers can’t afford to have buses or trucks off the road for long,” Church says.
“Because of our size, experience and network, we’ve got better access to parts, and we can get the job done quickly without compromising on quality.”
With a trans-Tasman footprint, a highly skilled workforce and an eye on future technologies and training, Royans is setting a benchmark for how a modern transport repair business can scale without losing its local focus.
“We’ve been going strong for 81 years now, and it’s this experience that keeps us one step ahead,” Church says.
Read more:
- Victorian driver strikes: One operator reaches agreement while one prepares for more strikes after unsuccessful negotiations
- Free travel and bus services retained in WA public transport commitment
- End of the line for diesel buses in WA
- Victorian communities embrace new bus network
- Major bus reforms coming for the NT