ConstraintMulti-site producer
Three plants
$100m+
Throughput improvement identified across the three largest sites. A complete bottleneck model for each site showed the cap sat in two upstream steps, not where management had been spending.
What we did: end-to-end bottleneck model per site, debottlenecking plan for the two capped processes.
TurnaroundIndustrial operator
Multi-shift
$53m
Annual recurring benefit from a full production and engineering reset — shift structure redesigned, spares readiness fixed, and mean time to repair cut by putting workshops closer to the work.
What we did: shift redesign, spares readiness, satellite workshops, live performance reporting.
Delivery PMOMajor capital project
$300m build
80 days
Commissioning pulled forward by 80 days, worth $50m, by shortening the critical path, tracking every long-lead item live, and managing contractor readiness before crews mobilised.
What we did: critical-path reduction, live materials tracker, contractor readiness gates.
Operating rhythmBulk logistics operation
Rail-linked
+19%
Nineteen percent more volume dispatched within four weeks. Reporting and a management operating system were built at every level of the organisation, and loading time per load fell 12%.
What we did: KPI tree by level, review cadence, loading-time analysis, live reporting.
Warehouse & logisticsField services operator
Remote sites
$11m
Annual recurring cost taken out of offshore logistics and warehouse operations, with a live model tracking where every item physically sat so material stopped being lost and reordered.
What we did: logistics planning redesign, warehouse operating model, live material tracking.
ThroughputProcessing operation
Plant and feed
$37m
Improvement initiatives sized by modelling plant and upstream performance together, which isolated the downtime and cycle-time losses actually worth chasing from the ones that looked bad but cost little.
What we did: integrated performance model, loss tree by cause, initiative sizing.
Investment caseTwo-asset group
Expansion case
19% → 27%
Expansion IRR lifted from 19% to 27% and over $10m identified to keep both sites operating, through a full asset-life model built across every revenue and cost lever.
What we did: full asset-life model, six IRR scenarios, sensitivity to yield and market price.
Capital decisionHeavy fleet operator
Replacement cycle
NPV +
A fleet automation programme that modelled NPV-negative was restructured into a positive case by scenario-modelling a phased replacement rather than a single switch-over.
What we did: NPV model off asset-level metrics, automated versus manned scenarios, phased roadmap.
Margin & pricingConsumer scale-up
$100m business
Full P&L
Margin, cost and pricing built from scratch for a fast-growing consumer business — the effect of every pricing experiment on volume and margin, margin by region and category, and true stock cost on a moving-average FIFO basis.
What we did: margin model, pricing experiment framework, FIFO stock costing, product recommender.
Client names withheld. Figures are as identified or realised on the engagement. The same methods, sized for the middle market.