Transform Your Existing Factory
Redesign layouts, flows, and work areas inside your current walls to unlock capacity, reduce movement, and improve safety.
The Brownfield Challenge
Most manufacturing facilities weren't designed with lean principles. Over time, they accumulate inefficiencies that drain productivity every day.
Common Issues We Solve
Accumulated inefficiencies that constrain your operations:
- Unplanned additions: Equipment added without layout planning, creating bottlenecks
- Excessive travel: Materials and operators traveling far due to poor adjacency
- Space constraints: Storage and WIP growing uncontrolled, limiting capacity
- Safety concerns: Congested aisles and unclear traffic patterns
What You Can Achieve
Typical impact ranges from brownfield projects:
- 30-50% reduction in material movement distance
- 20-40% reduction in work-in-process inventory
- 15-30% improvement in floor space utilization
- 20-35% reduction in operator walking
- Improved quality through better visibility and flow
- Enhanced safety with organized workspaces
Our Brownfield Optimization Process
Brownfield projects require surgical precision. We work within your existing constraints to find new efficiencies, often revealing capacity you didn't know you had.
Current State Assessment
Capture real flows and physical constraints to feed LFB‑based layout options.
Lean Diagnosis
Identify waste types, quantify movement distances, and analyze flow inefficiencies.
Spaghetti Diagram Analysis
Visualize material and operator paths to expose hidden transportation waste.
Future State Layout
Create an inside‑out layout where flow leads and structure follows.
Phased Implementation
Develop a step-by-step roadmap to minimize production disruption.
Implementation Support
Ensure the new layout is realized physically on the floor, not just on CAD.
Shop-Floor Optimization Services
LFB drives not just plant‑level layout, but also detailed workstation, material handling, and storage design
Workstation Design
Reduced fatigue and motion per cycle.
- Ergonomic worktable design
- Assembly station layouts
- Tool and material positioning
- Lighting and utility access
- Standard work documentation
Material Handling
Right‑sized systems for takt time.
- Custom trolley and cart design
- Conveyor system specification
- Crane and hoist requirements
- Gravity-feed solutions
- Presentation and replenishment
Storage Design
Controlled inventory with visual limits.
- Raw material storage calculations
- Work-in-process (WIP) sizing
- Finished goods warehousing
- Visual count-free stores
- FIFO flow racks
Spaghetti Diagram Analysis
Spaghetti diagrams bring the LFB philosophy to life by exposing the hidden, tangled paths inside your building
What is a Spaghetti Diagram?
A visual tool that traces the actual path materials and operators take through your facility. When multiple product paths are overlaid, the result looks like tangled spaghetti, revealing:
- Excessive travel distances
- Backtracking and crisscrossing
- Congestion points
- Opportunities for adjacency
The Impact
One client reduced their main product's travel distance from 847 meters to 94 meters through layout optimization guided by spaghetti diagram analysis.
Faster throughput with same resources. Lower handling costs and damage. Better visibility and control.
Equipment & Material Selection Support
When layout changes demand new equipment or handling systems, OptiSpace supports selection aligned with the new LFB‑based design
Equipment Procurement Support
Expert guidance during equipment selection:
- Specification development
- Vendor identification and evaluation
- Technical requirement documentation
- Quotation comparison support
- Trial and acceptance testing
Materials Guidance
Selection of appropriate materials and components:
- Fabrication material recommendations
- Finish and coating selections
- Supplier network access
- Cost-effective alternatives
- Quality and durability considerations
On-Floor Implementation Support
This ensures your team adopts the new ways of working and the gains are sustained, not lost after the project ends
Hands-On Guidance
Our consultants work alongside your team during implementation:
Training
- Demonstration of improved methods
- Procedure development
- Operator training
Support
- Trial runs and adjustments
- Problem-solving support
- Best practice transfer
Sustainability
- Visual management setup
- Standard work creation
- Sustainability planning
Transform Your Existing Factory
Unlock hidden improvement potential in your current facility. Get a structured LFB Pulse Check to identify layout optimization and flow improvement opportunities.