Engineering the Way
Your Business Works.
Manufacturing Systems Engineers and Industrial Engineers design, develop and implement efficient systems and processes. We apply those same formal disciplines to your operations — identifying constraints, eliminating waste and optimising throughput using data, not intuition.
A Formal Discipline for Optimising How Work Gets Done
Systems Engineering is the discipline of designing, developing and optimising the systems and processes within an organisation. Where general management consulting relies on frameworks and experience, Systems Engineering uses formal tools — Methods, Time and Motion analysis, process mapping, constraint identification, facility layout and ergonomics — to reach conclusions that are objective and repeatable.
The Company Founder is a formally qualified Manufacturing Systems Engineer — one of relatively few in Australia. That formal qualification is what separates our approach from generalist consulting.
The Tools We Apply to Your Operations
Manufacturing Systems Engineering draws on a range of formal tools and disciplines. Here is how we apply them.
Flow & efficiency analysis
Analysing and improving the flow of operations to ensure smooth and efficient processes. Identifying where work queues, waits or moves unnecessarily.
Methods, Time & Motion (MTM)
Formal tools to determine what reasonable throughput expectations should be for a given process. The foundation for setting targets and measuring performance.
Constraint management
Applying the Theory of Constraints to identify the one process that is limiting your overall throughput — and developing a plan to address it first.
Process mapping
Documenting current state and future state processes in a structured format that makes inefficiencies visible and improvement opportunities obvious.
Facility layout & ergonomics
Designing workspaces that support efficient, safe operations. Poor layout is a hidden cost in many businesses — one that is often straightforward to correct.
Equipment & tooling requirements
Identifying the machines, equipment, jigs and fixtures needed for accurate, repeatable and efficient production — and what can be eliminated.
Personnel & skills planning
Using Engineering first principles to determine staffing needs, define responsibilities and establish clear reporting structures.
Design & Process FMEA
Failure Modes and Effects Analysis applied at both the design and process level to identify and control failure risks before they occur.
Changeover optimisation
Reducing the time and complexity of changeovers between products, jobs or shifts — a common source of significant hidden capacity.
How a Systems Engineering Engagement Works
Structured, data-driven and focused on delivering measurable improvement.
Observe & measure
Time on the floor. Watching, measuring, timing and talking to the people doing the work. Data collected using formal tools, not impressions.
Analyse & model
MTM analysis, process mapping and constraint identification. Building a clear picture of how your system actually behaves and where the opportunities are.
Design future state
A proposed future state that addresses the identified constraints and inefficiencies — with alternative options where appropriate.
Implement & support
We support implementation, monitor progress and adjust as needed. We do not hand over a report and disappear.
What Systems Engineering Has Delivered for Our Clients
A selection of prior engagement outcomes across different industries and business types.
Aluminium Fabricator
3× more throughput with only a 40% increase in labour costs across the organisation. Revenue per person transformed from industry average to best-in-class.
Laminations Company
300% improvement in throughput using the same process, personnel and equipment — while also improving quality and equipment reliability.
Aerospace Jet Engine Service
Lead time reduced from 60+ days to around 21 days, including client authorisation of MROH activities.
Signage Company
Moved to a facility 60% larger. New layout designed to handle 260% more throughput with the same equipment and personnel.
Car Dealer Service Dept
Service throughput improved by 50%, worth around $480,000 per year in additional margin from the same service bays and team.
Complex Facility Relocation
Allowed two weeks to complete a complex manufacturing facility move. A carefully devised plan reduced production loss to just 4 hours.
Ready to Engineer a Better Way of Working?
If you wish to improve productivity, efficiency and profitability using the same or proportionally less resources, give us a call. That is exactly what we are qualified to help you achieve.
1300 00 IIAU (1300 004 428)