Up to 37%
Output Improvement
Increase production capacity within the existing facility.
Brownfield Redesign & Expansion Consulting
More capacity doesn't always require a larger facility. In many plants, significant growth is possible by improving flow, reducing constraints and using space more effectively.
We help manufacturers unlock hidden capacity and prepare their operations for future growth.
India | Middle East | Africa
Talk to Our Experts Today
Results Section
What You Gain
Up to 40%
Revenue Growth
Generate more revenue from existing assets and infrastructure.
Up to 300%
Expansion Capability
Unlock future growth potential without major facility investment.
Up to 82%
Material Movement Reduction
Reduce travel distance and improve operational flow.
Up to 30%
Productivity Improvement
Increase output per employee and production resource.
Up to 20%
Lead Time Reduction
Improve flow and reduce production cycle delays.
Pain Point Section
Do You Need More Capacity or Better Flow?
Capacity constraints limiting growth
Production demand continues to increase while the facility struggles to support additional volume.
Layouts developed over time
Equipment and processes have been added gradually without an integrated facility design strategy.
Excessive material movement
Poor flow creates unnecessary travel, handling effort, and operational waste.
Bottlenecks restricting throughput
A few constrained operations limit the performance of the entire facility.
Underutilized space
Available floor area, vertical space, and storage opportunities remain unused.
Expansion concerns disrupting operations
Growth initiatives are often delayed because facility changes appear too disruptive to production.
Previous expansions creating inefficiencies
Incremental additions have increased complexity and reduced operational flow.
Uncertainty around expansion decisions
Organizations lack clear data on whether to redesign existing facilities or invest in new infrastructure.
Solution Section
Where We Help You Succeed
Capacity & Constraint Analysis
Identify the true limitations preventing the facility from achieving higher output.
Bottleneck Elimination
Remove process constraints and improve throughput across critical operations.
Lean Layout Redesign
Reconfigure facility layouts to improve productivity, flow, and space utilization.
Material Flow Optimization
Reduce transportation, handling, and non-value-added movement throughout the facility.
Space Utilization Improvement
Recover unused floor space, storage areas, and vertical capacity.
Phased Expansion Planning
Develop expansion strategies that minimize operational disruption.
Expand-or-Build Business Cases
Evaluate the financial and operational benefits of expansion versus new facility investment.
Future-Ready Facility Layouts
Create scalable facility designs that support future growth requirements.
Our Approach
The Gemba Approach
A proven 5‑phase methodology delivered on your shop floor — not from a boardroom. Every phase is hands‑on, data‑backed, and measured against a signed baseline.
Assessment & diagnostics
A 2–4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.
Scope, deployment & commercials
Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.
Current state mapping & baseline
Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.
Proof of concept, implementation & on-site training
Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba in real conditions, under real pressure.
Sustenance & audit handover
Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.
We don't exit on a deadline. We exit when the results hold.
Every engagement includes audit handover and built‑in review systems.
Case Studies Section
Featured Case Study
Real project outcomes across brownfield redesign, with measurable capacity gains achieved within existing facilities.
Solar Manufacturing
37% Output Increase
A leading solar PV manufacturer increased daily production from 1,404 modules to 1,923 modules through bottleneck elimination, OEE improvement, TPM implementation, and facility flow redesign. The project delivered significant capacity gains without constructing a new facility.
1,404 → 1,923 modules/day37% output increaseNo new construction
Key Levers
- Bottleneck elimination
- OEE improvement
- TPM implementation
- Facility flow redesign
Aluminium Rolling Manufacturing
40% Revenue Growth
A large aluminium rolling operation redesigned production flow, reduced lead times, improved changeovers, and optimized workforce deployment. The initiative increased revenue by 40% while improving productivity and reducing operating costs.
40% revenue growthLead time reducedOperating costs lowered
Key Levers
- Production flow redesign
- Lead time reduction
- Changeover improvement
- Workforce optimization
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything companies usually ask before starting a Brownfield Redesign engagement.
What is Brownfield redesign?
Improving an existing facility layout to increase efficiency, flow, and operational performance.
Can Brownfield redesign increase production capacity?
Yes. Most facilities can unlock significant capacity without expanding their footprint.
Will production stop during implementation?
No. Improvements are typically executed in planned phases to minimize disruption.
What is the difference between Greenfield and Brownfield projects?
Greenfield involves building a new facility, while Brownfield focuses on improving an existing one.
Do you provide 2D and 3D layouts?
Yes. We provide both 2D layouts and 3D visualizations for planning and implementation.
How quickly can improvements be seen?
Most businesses begin seeing measurable improvements within 60–90 days.
Contact
Change Starts With
a Conversation
Fill out the form and let's discuss how Gemba Concepts can support your business transformation journey.