Industrial warehouse interior

Warehouse Improvement Consultancy — Melbourne

Your Warehouse Is Leaving Money on the Floor.

"I spent 15 years managing the Honda Logistics UK distribution centre. 750 cars a day manufactured. Now I bring that precision to your operation"

Book Your Free Discovery CallFree consultation. No obligation.
15
Years
Distribution Management
750
Cars/Day
Honda Production Line
2
Shifts
Zero Downtime Culture

The Foundation

What Is 6S?

6S is a Japanese workplace organisation methodology derived from the Toyota Production System. It's the foundation of every high-performing warehouse — and most Australian SMEs have never properly implemented it.

1S
Sort
Eliminate everything that doesn't belong. If it's not needed, it's in the way.
1
2S
Set in Order
A place for everything, everything in its place. Reduce search time to zero.
2
3S
Shine
Clean is not cosmetic — it's diagnostic. Dirt hides defects and danger.
3
4S
Standardise
Document the right way. Make the correct process the only process.
4
5S
Sustain
Discipline is a system, not a personality trait. Build habits that hold.
5
6S
Safety
Safety is not a poster on the wall. It's engineered into every process.
6
Organised warehouse shelving demonstrating 6S methodology
6S

The Differentiator

Most consultants stop at 6S. We don't.

Lean methodology fixes your floor. But if your culture is broken, your management is reactive, and your people aren't trained — the floor reverts in 90 days. I fix all three.

01

Efficiency

Systematic 6S implementation, flow optimisation, waste elimination, and KPI frameworks that actually get measured.

02

Culture

The invisible force that either sustains your improvements or destroys them. We build accountability from the ground up.

03

People

Management coaching, team training, and leadership development — because your best asset is the one clocking in every morning.

Theoretical warehouse picking path map showing optimised routing

The Credentials

15 Years. Honda Logistics UK. 750 Cars a Day.

I spent 15 years as Distribution Manager at Honda Logistics UK, supplying a live production line with car parts to build Honda Civics and CR-Vs. Every day, across two shifts, we delivered the right part to the right place at the right time — or the line stopped. That's not a theoretical framework. That's real operational pressure, at scale, with zero tolerance for error.

Now I bring that same precision to small and medium warehouses across Melbourne. If you're ready to stop firefighting and start running a warehouse that actually works, let's talk.

Honda Logistics UKDistribution ManagerMelbourne, Australia

Tips & Insights

Straight Talk from the Floor

Efficiency

The #1 Cause of Warehouse Inefficiency

It's not your layout. It's not your equipment. It's the thing hiding in plain sight that every manager walks past every single day.

Read more
6S

How 6S Transformed a Melbourne SME in 60 Days

A 12-person warehouse, 40% pick error rate, and a team that had stopped caring. Here's what changed — and what didn't.

Read more
Culture

Why Culture Kills Efficiency Before Layout Does

You can reorganise the floor, buy new racking, and retrain the team. If the culture is wrong, it all reverts. Every time.

Read more
Franky Ford — founder of Beyond 6S Consulting

Why I Do This

“
I don't just consult — I work alongside you. Your success is my success.

I built this business on three things: honesty, integrity, and a genuine care for the people I work with. I'll tell you what your warehouse actually needs — not what sounds impressive. I'll be straight with you about what's working and what isn't. And I'll stay in it with you until we get the result you're after.

Honesty
Straight talk, no fluff. You'll always know where things stand.
Integrity
I do what I say. Every time, without exception.
Genuine care
Your team, your culture, your business — I'm invested in all of it.
Succeed together
I don't walk away when it gets hard. We see it through.
Franky Ford
Founder, Beyond 6S Consulting

Ready to Stop Losing Time and Money?

Book a free 30-minute discovery call. No pitch, no pressure — just an honest conversation about what's holding your warehouse back.

Free 30-minute call. Melbourne-based. Remote available.

Beyond 6S Consulting

Operational excellence that goes beyond the floor. Efficiency, culture, and people — built to last.

Melbourne, Australia

Get Started

Ready to transform your warehouse operations? Book a free 30-minute discovery call.

Book a Free Call

© 2026 Beyond 6S Consulting. All rights reserved.

Melbourne, Australia