Manufacturing Facility and Process Optimization

The movement of material and positioning of value-added operations have a big impact on cost. Group50’s plant layout consultants have years of lean manufacturing experience in optimizing factories and distribution centers in companies such as GE, Black & Decker, Sunbeam, P&G and many others.  We have completed projects in these areas:

  1. Work station design
  2. Factory consolidation
  3. Factory relocation including site selection and factory build out
  4. Automation and Robotics – Industry 4.0 & Industry 5.0
  5. Machining centers
  6. Material flow
  7. Application of Six Sigma techniques (TAKT, 5S, Andons, SPC, Visual Instruction, Poke a Yoke,  etc.)
  8. Make vs. Buy analysis
  9. Line certifications
  10. Quality systems

We use multiple techniques including material flow modeling, Value Stream Mapping, Kaizen, Continuous Improvement programs and others. Our plant layout consultants have deep experience in utilizing the latest technologies and best practices in manufacturing facilities such as:

  1. Application of IoT, AI, Machine Learning
  2. Blockchain
  3. Supply chain technology (MRP, WMS, Shop Floor Control, etc.)
  4. Equipment, tooling and component sourcing
  5. Preventative Maintenance
  6. Quick Change Die strategies

We have built plants in Malaysia, the Czech Republic, China, Mexico and the United States, Canada and others. We are project management experts and have the ability to work with our clients from start to finish.  The following are some project highlights:

  1. Redesign of an LED lighting factory including material flow, stores and work centers
  2. The design of a complete manufacturing system for a firearm company (work stations, testing, incoming operations, material stores and the entire technology backbone for manufacturing)
  3. Redesign of a factory for a battery pack manufacturer
  4. Optimized the work and material flows for a furniture manufacturer
  5. Restructured the shop floor for a BBQ Grill factory from batch processing to continuous flow including product designs, pack lines, the relaunch of their MRP system and material stores design
  6. Designed work cells for a needleless injection product so that the cells could be moved to any country to produce product
  7. Designed and implemented automated lines to produce 9 million units of a famous CPG product
  8. Designed the clean rooms and factory floor for a high speed baggage inspection system

You can read about other projects here.

Our plant layout consultants understand Lean Manufacturing and how to leverage the intersection of people, process, information technology and automation & robotics to:

  • Increase productivity
  • Optimize costStrategy 5.0 requires optimizing a business at the intersection of people, process, information technology and cobotics along with a robust organizational development program following the Group50 change management framework called the Business Hierarchy of Needs
  • Minimize working capital.
  • Reduce lead times.
  • Ensure high quality levels.
  • Leverage technology.

Group50 provides training workshops for the various systems and skill levels required to effectively operate a newly designed factory, work cell or system.  To find out more, call one of our plant layout consultants at (909) 949-9083, drop us a line at or request more information here.

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