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.
Strategic Takeaway
- Layouts designed for flow usually need less space and deliver more output.
- Storage density and movement design must be solved together.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
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Bengaluru
Ram Leo, 59/4, Market Rd, Basavanagudi, Karnataka 560004
Ahmedabad
World Trade Tower, Near Sarkhej Sanand Cross Road, Gujarat 380051
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