Company & Role Overview

• Auckland Flashing Solutions (AFS) was originally a traditional, manually operated metal fabrication workshop, specializing in mechanical waterproofing and façade solutions.
• In 2019, AFS became the manufacturing arm of CIS Group, requiring a complete operational and digital overhaul.
• Transitioned from analogue production to a fully digital CNC-driven operation, integrating ERP-like workflow automation to optimize scalability and efficiency.

Industry & Market Conditions at the Time

• The market did not demand digital manufacturing at the time, but adopting automation was critical for long-term growth and efficiency.
• Analog methods led to high material waste, slow production, and inconsistent quality, making the traditional approach unsustainable.
• Increasing demand for custom mechanical waterproofing and façade solutions required a shift toward precision-driven, digitally integrated fabrication.

Your Entry into the Role (Challenges, Expectations, and Initial Goals)

• AFS required a full-scale digital transformation to remain competitive and scalable.
• Existing operations were manual and inefficient, creating bottlenecks in production, procurement, and cost tracking.
• Workforce adaptation to new technology and processes was a significant challenge.
• No structured digital workflow, leading to production inconsistencies and communication inefficiencies.

Day-to-Day Operations

• Managed daily production workflows, ensuring CNC-driven fabrication precision.
• Optimized supply chain logistics, reducing lead times and procurement costs.
• Led a multi-disciplinary team, ensuring alignment with Agile manufacturing principles.

Key Strategic Initiatives Led

• Appointed a Workshop Manager (Metallurgical Engineer) to lead CNC transition and production optimization.
• Hired a 3D Designer/Drafter to standardize CNC-ready digital workflows.
• Developed a structured pricing model, ensuring accurate financial forecasting and job costing.

Stakeholder & Team Leadership Dynamics

• Upskilled the existing workforce, ensuring a seamless transition from manual to digital manufacturing.
• Strengthened client relationships, integrating real-time job tracking to increase trust and reduce miscommunication.
• Secured preferred supplier status with Tier 1 construction firms, solidifying AFS’s market position.

Unique Business & Leadership Strategies Implemented

• Built a fully functional ERP-like system without the need for expensive enterprise software.
• Applied lean manufacturing principles, optimizing workflows and cost structures.
• Designed a Trello-based tracking system, enhancing production visibility and customer engagement.

Risk & Compliance Mindset

• Ensured full compliance with mechanical waterproofing regulations, minimizing risk exposure.
• Developed a real-time cost control framework, reducing financial uncertainty and project overruns.
• Toyota consultant validation confirmed AFS’s world-class workflow efficiency and zero operational inefficiencies.

Lessons Learned & Industry Best Practices

• Digital transformation is a competitive necessity, even in markets where automation is not yet widely adopted.
• SMEs can build ERP-level efficiencies with affordable, agile technology solutions.
• Customer transparency via digital job tracking enhances client trust and reduces operational disputes.

• Digital CNC Overhaul & ERP Integration – Increased revenue from $1.2M to $2.5M+ annually.
• Market Positioning as a Tier 1 Supplier – Secured preferred contractor status with Tier 1 firms.
• Lean Manufacturing Initiative – Reduced waste by 25% and cut procurement costs by 15%.
• Toyota Consultant Validation – Achieved world-class workflow efficiency certification.