Plant Design & Expansion
Design the plant around how work needs to flow.
From greenfield facilities to brownfield expansion, Gemba translates demand, process, material movement, equipment and operating requirements into a plant that can run efficiently and scale with less friction.
A layout decision becomes an operating condition.
- Long material travel
- Space feels constrained
- WIP accumulates
- Expansion disrupts operations
- Safety and access conflicts
- Process sequence and adjacency are working against flow.
- Storage, aisles, utilities or future capacity were not planned together.
- Layout and process flow are creating waiting or cross-movement.
- Brownfield changes are being added without a whole-flow view.
- People, equipment and material routes compete for the same space.
What we design.
Greenfield Plant Design
Translate process, capacity and future growth into a complete operating layout.
Brownfield Redesign & Expansion
Reconfigure an operating facility while protecting continuity and future capacity.
Layout & Material Flow
Improve adjacency, travel, storage, staging and movement.
Capacity & Utilities Planning
Align equipment, utilities, support areas and capacity requirements.
Implementation Support
Carry layout decisions through detailed planning and execution coordination.
Design from the operation outward.
Start with demand, process and capacity. Then determine equipment, material movement, people and safety before fixing the layout — with future expansion built in.
01
Demand & Product Mix
02
Process
03
Capacity
04
Equipment
05
Material Flow
06
People & Safety
07
Layout
08
Future Expansion
Designed for how the operation will actually run.
Industrial Businesses Across 3 Continents