> Plant Layout Design

Plant Layout Design

Our team improves operational efficiency by analyzing workflows, reducing costs, and aligning resources to your business goals.
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What We Do

Manufacturing Facility Design

Our experts design future-ready industrial layouts optimized for space, flow, and throughput, whether greenfield or brownfield.

Real World Impact

Results That Drive Transformation

At Gemba Concepts, we empower businesses to achieve operational excellence through customised lean strategies, practical process improvement solutions, and hands-on execution designed to drive measurable results.

Double the production output without adding shifts

Increased capacity for scaling operations

Better ergonomics and smoother assembly flow

Reduce footprint, freeing up 12,000 sq. ft.

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Our Process

Our Consulting Approah

We partner with businesses across India and beyond, delivering hands-on, on-site consulting rooted in Toyota’s proven practices. Our flexible engagement model includes diagnostics, implementation, training, and audit support customised to your pace and goals, delivered through in-person collaboration, virtual meetings, and continuous communication.

Assessment/Diagnostics

We conduct a 2-4 days on-site evaluation to identify gaps and improvement opportunities.

Scope Document, Deployment & Commercials

We define project scope, align deployment strategy, and finalize commercials.

Present State Mapping & Baseline

We map current processes, establish performance baselines, and secure client sign-off.

Proof of Concept, Implementation & On Job Training

We implement pilot solutions and train teams directly at the Gemba for real-time impact.

Sustenance & Audit Handover

We ensure sustainability with audits, reviews, and knowledge transfer to client teams.

Case Study

We helped a greenfield aerospace component plant design its manufacturing layout using Lean flow principles. The facility achieved 20% space savings and optimized material handling paths.

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