Manufacturing & construction consultants · Melbourne
Faster factories. Bigger margins. A business that runs without you.
We find the waste, lift output and margins, then build the systems that keep it running, so the gains last and you can finally step back.
20+ years
improving operations in Australia and overseas
Master Black Belt
Lean Six Sigma
Engineer
degree-qualified in manufacturing
Hands-on
we implement, not just recommend
Sound familiar?
A busy factory, thin margins, and everything runs through you
- Orders are up, but the factory can’t keep pace
- Revenue is growing, but margins aren’t
- The layout made sense five years and three machines ago
- Jobs run late, and you find out when the customer calls
- Every decision still comes back to you
- You’ve tried to step back, and quality or deliveries slipped
What we do
Fix the floor. Then build the system that keeps it fixed.
Faster processes slide back without management systems. Systems laid over a messy factory only document the mess. We do both, in that order.
A faster, leaner factory
- Factory layout design →Layouts for growth, relocation or new machines, designed around how work flows, with the fit-out managed if you need it.
- Cycle time & bottlenecks →Find the steps that set your output, remove the waste in them, and balance the line so output grows without new staff or machines.
- Lean manufacturing →Hands-on lean implementation led by a Master Black Belt: waste removal, 5S, standard work and root cause problem solving.
Systems that run without you
- Business systems & SOPs →The systems that let the business run without the owner: order-to-production tools, procedures, clear roles and handover plans.
- KPIs & dashboards →Live dashboards for output, defects and rework, plus daily huddles and escalation paths, so your team manages performance without you.
- Scheduling, dockets & invoicing →For construction service businesses: automated bookings, scheduling, digital dockets and invoicing, built into the systems you already use.
How it works
We don’t hand you a report and leave
- STEP 1
Factory review
We spend time on your floor, time every step and find where the hours and dollars go, including where the business depends on you.
- STEP 2
Fix the flow
Layout, bottlenecks and waste first, so the system is built on a process that works.
- STEP 3
Systemise
Scheduling, dashboards, standard work and roles, so decisions stop landing on your desk.
- STEP 4
Hand over
Your team runs it while we coach. You step back in stages, with the numbers to show it’s holding.
Results
What changes for our clients
40 → <4
manager hours a week
Door manufacturer: from manager-dependent to system-governed
Manager firefighting cut from 40+ to under 4 hours a week, and order admin cut by 95%.
2 → 10
truss sets a day
Truss plant: 2 to 10 truss sets a day
A new production system, tooling and labour model, plus the costing behind a large tender.
New factory
layout, fit-out & operations
Frames Now: a new factory, end to end
Layout design, physical fit-out and optimised operations, delivered as one project.
Testimonials
What clients say
“Paul exceeded our expectations by delivering an end-to-end project that significantly increased our factory’s output. His expertise in designing a new factory layout, managing the physical fit-out, and optimising operations was exceptional. I highly recommend Paul to deliver outstanding results and transformative improvements.”
“Paul successfully delivered a comprehensive solution to increase production from 2 to 10 truss sets per day. Paul’s expertise in designing a new production system, determining tooling requirements, analysing labour costs, and calculating setup costs for a large tender was instrumental in our success. Highly recommended for exceptional problem-solving and efficiency improvement.”
“Paul proved to be an exceptional problem-solver, successfully resolving a processing issue that had eluded all previous attempts. His insight and determination resulted in improved performance and delivered over $350k to our bottom line. We will definitely engage Paul’s services again.”
Who we work with
Owner-run manufacturers and builders
Usually 5 to 50 staff, where the owner is still the person everything runs through.
Where we work
Melbourne-based, on site across Victoria
We work on site across Melbourne, Geelong and regional Victoria, and have delivered projects for businesses across Australia.
Find out what's keeping you on the floor
A free 30-minute call is the first step. We'll talk through your operation and whether a factory review makes sense.