A champion of Australian engineering standards and capabilities is putting his beliefs into practice by investing in advanced 3D modelling to produce complex low voltage switchboards with reduced waste and improved safety, sustainability, and cost-efficiency.
Matt Izadi and his team at All Switchboards in Rouse Hill are applying the technology to industrial, commercial, residential, data centre, and electric vehicle charging switchboards that will meet challenges to the grid and existing infrastructure in the years immediately ahead.
All Switchboards and its team of two electrical engineers, two mechanical engineers, and six highly skilled fitters has doubled the size of his business over the last two years. It is already planning to expand its facilities and capabilities again, as the company’s advanced 3D modelling and quality manufacturing technologies are taken up by both repeat customers and, increasingly, some of the biggest building and infrastructure specialists in the country.
“We have definitely caught the attention of some of the majors – tier one companies – as they have seen what sophisticated, flexible, and time-saving products we are already producing for our valued long-term customers. Typically, new customers will give us a smaller job first, which is smart, then they will trust us with bigger tasks,” says Matt, who had to re-launch his career in Australia after leaving his native Iran as a high-ranking automotive electronics engineering specialist and return to the production floor here to work his way up again.
“My employers in Australia treated me well and we shared my values of strong Standards, rigorous quality control and technology innovation to get the right result first time and every time.
“I owe the local switchboard manufacturing industry for giving me the start to make my own way with my first company in 2021,” says Matt. That original company doubled in size within two years and the new premises at Rouse Hill are already going to need extensions or replacement as Matt and his 10-person team turn their attention to demanding but rewarding challenges that lie ahead for the switchboard industry. These include catering to the rapidly expanding needs of data centres and EV charging switchboard technology at one end of the spectrum, plus a strong demand at the other end of the scale for sub-1000amp technologies for industrial, commercial and multi-unit residential buildings.
“There are waves of change sweeping through the switchboard manufacturing industry – EVs, energy and materials sustainability, safety, and essential standards such as AS/NZS 61439 Standards for low-voltage switchboards, and the associated initiatives promoted by NESMA. NESMA’s striving to advance standards that are now statutory requirements advances the industry and protects our customers by doing so.
“Progress isn’t real progress if short-term opportunists take shortcuts to make a short-term profit. The costs of this don’t disappear. The results of and liability for poor Standards, poor safety and poor planning for the future are just passed down the line to the customer, exposing the customer to risk when problems need to be rectified or maintenance needs to be done. That’s when non-compliance with Australasian standards will often be discovered, and problems will come to roost.
“The bright side of the coin is that we have some wonderful technologies available to us as engineers to lift Standards, to lift quality, and to increase cost-efficiency and sustainability as we immerse ourselves in the digital Industry 4.0 revolution. This revolution is absolutely real and tangible today – we deal with it every day in 3D modelling, which enables us to precisely configure and lay out the ideal switchboard for a job before we have to cut a gram of copper, steel, or cable. You can literally see any problems before they arise.
“Also, and importantly, a customer can come in and see their product taking shape on the screen, can see the inputs and outputs, and get involved in a way he or she never could before. If they can see a new need emerging, or a better way to do something for their industry application, they can say “What about this” or What about that?” It gives them great confidence that they are getting the best fit for their needs. And it saves re-engineering and the time costs of the physical changes.
“Our guys on the shop floor appreciate the technology too, because it will map out in detail what to cut, where to cut, how to assemble – saving huge amounts of time while making best and sustainable use of precious resources and materials. All that laborious time-consuming job of measuring and cutting is taken out of the job, and we can focus on building in the best safety, sustainability, Standards and reliability.
“And a real beauty of the 3D system is that you can design-in and embed statutory Standards from the outset, then trace them all the way from planning, production, commissioning and service.
“Even years down the line, the traceability of compliance is recorded there, chapter and verse. And this is important, because Australian engineering is generally of a very high standard. But if there are any operators who think it might be easier to not pay attention to statutory standards, and do it the way they always used to, well they will have the spotlight shone on them when the product is examined for safety, compliance, and suitability for purpose.
“Traceability and compliance failures will show up right down the line. The big electricity distributors – Ausgrid, Endeavour, Essential Energy, for example – they are just not going to certify technology that is not up to Standard. And the long reach of traceability will go right down the line to when technology needs service, upgrading, or adaptation to changing needs.”
All Switchboards is investing in modelling, design and manufacturing technologies includes designing new sub-1000 amp switchboards that will respond better to future needs than standard modular designs.
“We have invested probably 1000 hours into this so far, because we believe we can make a true difference in the market in this area. Certainly, we focus also on the big end of the market, but there are plenty of industrial, multi-unit domestic and commercial applications that will face new needs for quality, Standard-compliant technology. Shopping centres, carparks, distribution facilities, for example, will have multiple challenges with evolving HVAC changes, EV demands, energy saving, lighting and multi-tenancy issues.
“We find it is important to look ahead to see where the future is headed, across a spectrum of markets, smaller and larger, so we will have the answers ready to go as the needs arise. Forward thinking, and building top Standards into future product, is a major advantage for the industry, and for our customers.”
