Front line · factory layout design
Factory layouts designed around how work actually flows
Most factory layouts grew one machine at a time. We design layouts that cut walking, double handling and searching, and leave room to grow, then help you make the move.
Signs your layout is costing you
- Product travels back and forth across the floor between steps.
- Forklifts and people are always in each other’s way.
- Work in progress piles up in aisles and corners.
- Operators walk to fetch materials, tools or the next job.
- You need more output, a new machine, or a bigger site, and don’t know where it all goes.
How we design a layout
- Measure the current flow. We map how each product moves through the factory and time each step.
- Balance the line first. We work out how many stations you need and how work is split between them, so the layout supports single-piece flow instead of batches.
- Design the layout. Stations in sequence, materials at the point of use, clear aisles, and space for the next stage of growth. We draw it to scale.
- Model the options. Where it helps, we compare layouts for different crew sizes or volumes, with the cost and output of each.
- Manage the move. We can plan and manage the physical fit-out so production keeps going during the change.
Results
For Frames Now, Paul designed a new factory layout, managed the physical fit-out and optimised operations as one project. "His expertise in designing a new factory layout, managing the physical fit-out, and optimising operations was exceptional." Glenn Vardy, Director.
Planning a move or expansion?
The best time to get the layout right is before the machines are bolted down. We also build the business case: new equipment return on investment, future operating costs, and staged output targets.
Common questions
+Can you design a layout for a new site we haven’t moved into yet?
Yes. We work from the building plans and your product flows, and can manage the fit-out once you have the keys.
+Do you provide CAD drawings?
Yes. Layouts are drawn to scale, showing stations, racking, aisles and material flow.
+Do you only do layouts for manufacturers?
Mostly manufacturing and building products: doors, frames and trusses, joinery, fabrication and precast. We also design warehouse and dispatch areas.
Find out what's keeping you on the floor
A free 30-minute call is the first step. We'll talk through your operation and whether a factory review makes sense.