A Facility Designed for 2.7X the Output
A valve manufacturer planned capacity from flow logic first, increasing planned output from 1,242 to 3,372 units/day before construction.
1,242 → 3,372
Planned units/day
2.7x planned capacity
2.7x
Capacity
Single-piece flow
Design principle
Reduced
Movement
The Situation
The existing flow doubled back and drove excess internal movement.
Capacity was treated as a footprint problem instead of a movement-and-flow problem.
Replicating the old layout in a larger shell would have scaled inefficiency.
What We Did
We designed the future plant around ideal part movement before fixing walls and equipment positions.
- Engineered facility flow around single-piece movement.
- Optimized material movement before locking layout boundaries.
- Created production planning architecture that scales with demand.
The Results
Planned capacity increased from 1,242 to 3,372 units/day (2.7x) with reduced cycle and movement burden.
Constraints were removed at design stage before civil commitment.
- 01
The cheapest time to fix layout is before construction.
- 02
Greenfield projects are the one chance to avoid inheriting old plant compromises.
Industrial Businesses Across 3 Continents