Less Raw-Material Space, More Boxes per Shift
A Fortune 1000 packaging operation cut raw-material storage from 50,000 to 38,000 sq ft while output increased from 12 to 25 boxes per shift.
50,000 → 38,000
Raw-material storage (sq ft)
Output increased in parallel
50k → 38k sq ft
RM storage
12 → 25 boxes/shift
Production
U-shaped movement
Flow
Selective + cantilever
Racking
The Situation
Raw material and production competed for the same floor, with storage consuming disproportionate area.
Material flow doubled back, and planning treated space growth as the only path to capacity.
The five-year plan required better utilization before bigger footprint.
What We Did
We designed around movement first, then sized storage to support that flow.
- Ran value-stream mapping and five-year capacity evaluation.
- Designed a U-shaped flow to reduce travel and crossing.
- Applied selective and cantilever racking based on load profile.
The Results
Raw-material storage reduced by 12,000 sq ft while output more than doubled to 25 boxes per shift.
The layout now supports planned growth without acquiring additional floors.
- 01
Layouts designed for flow usually need less space and deliver more output.
- 02
Storage density and movement design must be solved together.
Industrial Businesses Across 3 Continents