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.
Strategic Takeaway
- The cheapest time to fix layout is before construction.
- Greenfield projects are the one chance to avoid inheriting old plant compromises.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
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