Design Manufacturing Facilities That Improve Flow, Capacity, and Productivity

“Setting up a new plant is the one opportunity you have to get everything right from day one. We engaged Gemba at the design stage and it made a fundamental difference. They validated every layout decision through KPI modelling - rack lengths, production areas, material flow paths - before a single machine was placed. Total production capacity went from 1,242 to 3,372 valves per day and space efficiency improved 43%. The facility was built to perform, not corrected after the fact.”

“We had a greenfield opportunity and one chance to plan it correctly. Gemba brought a level of rigour we had not encountered before - process flow mapping, equipment sequencing, inventory strategy across RM, WIP and FG, racking calculations, and 3D layout validation. What was delivered was not just a layout. It was an operational blueprint designed for how we actually intended to run the plant.”

“Most consultants hand you a layout and leave. Gemba stayed through concept, design, and execution. They mapped the production flow, identified bottlenecks before they were built in, standardised the man-to-process ratios, and designed the facility around future scalability. The result was a plant that operated at target throughput in far less time than we had expected.”

“A greenfield plant in healthcare manufacturing cannot afford poor layout decisions - compliance, material traceability, and contamination control are built into the design. Gemba understood that. They designed the facility with unidirectional material flow, proper zoning for production and storage, and space planning that met both operational and regulatory requirements. It was a genuinely thorough exercise.”

“We were building a new production facility and had an internal team working on the layout. Gemba came in, reviewed the plans, and within days identified cross-movement issues, wrong equipment placement, and space allocation decisions that would have caused us problems for years. They redesigned the flow, ran proof of concepts for the critical assembly areas, and the facility launched significantly closer to target output than our original projections.”

“Our greenfield expansion required consolidating three production lines into a single facility without disrupting live operations. Gemba designed the master layout blueprint, ensured unidirectional material flow across all lines, and planned RM and FG storage so the facility could operate without external warehousing dependency. The manufacturing control we gained from having everything under one roof - designed correctly - was immediately visible in output and coordination.”

“Setting up a new plant is the one opportunity you have to get everything right from day one. We engaged Gemba at the design stage and it made a fundamental difference. They validated every layout decision through KPI modelling - rack lengths, production areas, material flow paths - before a single machine was placed. Total production capacity went from 1,242 to 3,372 valves per day and space efficiency improved 43%. The facility was built to perform, not corrected after the fact.”

“We had a greenfield opportunity and one chance to plan it correctly. Gemba brought a level of rigour we had not encountered before - process flow mapping, equipment sequencing, inventory strategy across RM, WIP and FG, racking calculations, and 3D layout validation. What was delivered was not just a layout. It was an operational blueprint designed for how we actually intended to run the plant.”

“Most consultants hand you a layout and leave. Gemba stayed through concept, design, and execution. They mapped the production flow, identified bottlenecks before they were built in, standardised the man-to-process ratios, and designed the facility around future scalability. The result was a plant that operated at target throughput in far less time than we had expected.”

“A greenfield plant in healthcare manufacturing cannot afford poor layout decisions - compliance, material traceability, and contamination control are built into the design. Gemba understood that. They designed the facility with unidirectional material flow, proper zoning for production and storage, and space planning that met both operational and regulatory requirements. It was a genuinely thorough exercise.”

“We were building a new production facility and had an internal team working on the layout. Gemba came in, reviewed the plans, and within days identified cross-movement issues, wrong equipment placement, and space allocation decisions that would have caused us problems for years. They redesigned the flow, ran proof of concepts for the critical assembly areas, and the facility launched significantly closer to target output than our original projections.”

“Our greenfield expansion required consolidating three production lines into a single facility without disrupting live operations. Gemba designed the master layout blueprint, ensured unidirectional material flow across all lines, and planned RM and FG storage so the facility could operate without external warehousing dependency. The manufacturing control we gained from having everything under one roof - designed correctly - was immediately visible in output and coordination.”

“Setting up a new plant is the one opportunity you have to get everything right from day one. We engaged Gemba at the design stage and it made a fundamental difference. They validated every layout decision through KPI modelling - rack lengths, production areas, material flow paths - before a single machine was placed. Total production capacity went from 1,242 to 3,372 valves per day and space efficiency improved 43%. The facility was built to perform, not corrected after the fact.”

“We had a greenfield opportunity and one chance to plan it correctly. Gemba brought a level of rigour we had not encountered before - process flow mapping, equipment sequencing, inventory strategy across RM, WIP and FG, racking calculations, and 3D layout validation. What was delivered was not just a layout. It was an operational blueprint designed for how we actually intended to run the plant.”

“Most consultants hand you a layout and leave. Gemba stayed through concept, design, and execution. They mapped the production flow, identified bottlenecks before they were built in, standardised the man-to-process ratios, and designed the facility around future scalability. The result was a plant that operated at target throughput in far less time than we had expected.”

“A greenfield plant in healthcare manufacturing cannot afford poor layout decisions - compliance, material traceability, and contamination control are built into the design. Gemba understood that. They designed the facility with unidirectional material flow, proper zoning for production and storage, and space planning that met both operational and regulatory requirements. It was a genuinely thorough exercise.”

“We were building a new production facility and had an internal team working on the layout. Gemba came in, reviewed the plans, and within days identified cross-movement issues, wrong equipment placement, and space allocation decisions that would have caused us problems for years. They redesigned the flow, ran proof of concepts for the critical assembly areas, and the facility launched significantly closer to target output than our original projections.”

“Our greenfield expansion required consolidating three production lines into a single facility without disrupting live operations. Gemba designed the master layout blueprint, ensured unidirectional material flow across all lines, and planned RM and FG storage so the facility could operate without external warehousing dependency. The manufacturing control we gained from having everything under one roof - designed correctly - was immediately visible in output and coordination.”