Lean & Six Sigma
- Continuous Improvement
- Process Capability
- Operational Excellence
Based in New Zealand. Working with clients globally.
Lean Six Sigma Black Belt driven engineering expertise across advanced manufacturing, process optimisation and technology development.
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Your processes are inconsistent, and you don't know why.
Six Sigma root-cause analysis that finds where inefficiency actually lives.
Building new processes? Get them right the first time.
Lean-driven process design that works from day one, without re-engineering later.
New technology or equipment needs to run efficiently from day one.
Process trials and industrialisation support that de-risk new capability before rollout.
If any of this sounds familiar, we're the right team to talk to.
Every project runs through DMAIC: Define, Measure, Analyse, Improve, Control, our structured method for solving the problems that matter. Once under control, the cycle repeats. That's continuous improvement in practice, not just a slogan.
Clarify the problem, the process boundaries and what success looks like.
Collect real process data to establish a factual baseline, not assumptions.
Identify the root cause through statistical and process analysis, not guesswork.
Design and implement the fix, validated through trials before full rollout.
Lock in the gain with monitoring and process controls, so it doesn't drift back.
DMAIC isn't a one-time fix. Once a process is under control, the cycle starts again. Continuous improvement, built in.
Delivering engineering solutions from concept to industrial implementation.
A selection of engineering projects delivering measurable value in manufacturing and product industrialisation.
Implementation of a new orbital milling process for high-quality bore holes in carbon and glass fibre reinforced automotive structural components, developed through Six Sigma process optimization.
Development and testing of a full-ceramic silicon nitride end mill for high-speed machining of carbon and glass fibre reinforced plastics, a viable, resource-efficient alternative to cemented carbide.
A Six Sigma driven turning investigation into a particle reinforced titanium matrix composite, identifying the cutting tool and process parameters governing material removal rate and surface quality.
A Lean Six Sigma project that traced excessive cemented carbide rod deflection to sintering plate geometry and cut scrap costs by more than NZ$555,000 per year.
Development and industrial implementation of a complete thermal zinc reclaim recycling line for closed-loop cemented carbide manufacturing.
Complete engineering and industrial implementation of a fully automated extrusion line for high-precision cemented carbide rods.
Simulation-driven development and industrialisation of a new cemented carbide product family with 48 precision geometries.
Technical specification and supplier coordination for a new double-Z kneading machine, developed in cooperation with Hermann Linden Maschinenfabrik.
Selection and pre-series validation of a new micro-vacuum extrusion system for complex, small-diameter cemented carbide geometries, developed in cooperation with ECT-Kema GmbH.
Technical specification and industrialisation of a modular handling system for cemented carbide extrusion rods, developed in cooperation with Haginger Maschinenbau.
A tool design and root cause investigation programme that eliminated cracking at the direct pressed chamfer in cemented carbide dry pressing while raising press productivity.
Engineering expertise developed through more than 14 years in manufacturing and product development.
Founder and Principal Engineering Consultant at BS PM Solutions, combining a PhD in mechanical and production engineering with more than 14 years of hands-on experience in cemented carbide manufacturing, tool development and engineering leadership.
PhD,
Technical University Berlin
14+ Years R&D,
Production & Leadership
Six Sigma Black Belt
Process Optimisation and Manufacturing Engineering
Whether you're looking for support in Six Sigma process optimisation, quality management, advanced manufacturing or technology development — including specialist expertise in powder metallurgy — let's discuss how engineering can improve your manufacturing performance.