LFB Post-Commissioning Support
Your success doesn't end when the facility is built – it begins there, when the LFB design meets real‑world operations
Beyond Design & Construction
Post‑commissioning support from OptiSpace ensures your Lean Factory Building (LFB) design translates into stable, high‑performing daily operations
The Critical Transition Phase
A well-designed facility is just the foundation. The real challenge lies in:
- Transitioning from old to new facility without disrupting operations
- Training teams on new layouts and processes
- Implementing visual management systems
- Establishing production planning rhythms
- Optimizing supply chain for the new flow
- Fine-tuning operations based on real-world feedback
Our team bridges the critical gap between architectural drawings and day‑to‑day operations.
Why Continued Support Matters
Facilities designed with LFB principles achieve faster and more stable performance when supported by experts through this transition phase.
- Faster ramp-up to full production capacity
- Higher adoption of new processes and layouts
- Better sustainability of lean improvements
- Quicker resolution of operational issues
- Continuous improvement culture development
We stay with you through the critical months after commissioning.
Factory Shifting Assistance
Moving a factory is a high-risk operation. When moving into an LFB‑designed facility, we help ensure equipment placement, material flows, and line-side stocking match the intended design exactly.
Pre-Move Planning
- Detailed relocation schedule
- Equipment moving sequence
- Inventory transition planning
- Critical path identification
- Risk mitigation strategies
- Contingency planning
During the Move
- On-site coordination support
- Equipment placement verification
- Layout conformance checks
- Issue resolution
- Progress tracking
- Communication facilitation
Post-Move Optimization
- Fine-tuning of layouts
- Ergonomic adjustments
- Material flow validation
- Bottleneck resolution
- Performance verification
- Lessons learned documentation
Outcome: This reduces ramp‑up time and avoids the early chaos often seen in new facilities.
Phased Transition Options
We help you choose the right moving strategy:
Big Bang Move
Complete transition over a short shutdown period. Best for:
- Smaller facilities
- Scheduled production breaks
- When old facility must close immediately
Phased Migration
Gradual transition over weeks or months. Best for:
- Large complex facilities
- Continuous production requirements
- When you can run both facilities temporarily
Visual Factory Deployment
A well-designed layout should speak for itself. Visual factory deployment makes the LFB layout self‑explaining, allowing operators and supervisors to manage by sight, reducing training time and errors.
What is a Visual Factory?
A workplace designed so that anyone can understand the status of operations at a glance, without asking questions or checking computer systems.
Visual management transforms your factory floor into a self-explaining, self-regulating system where problems surface immediately and solutions are obvious.
Core Visual Elements
- Floor markings and traffic flow indicators
- Location labels and address systems
- Standard work instructions at workstations
- Inventory level indicators
- Quality alert systems
- Safety and housekeeping standards
Visual Work Instructions
Clear, picture-based instructions at each workstation showing:
- Operation sequence
- Quality checkpoints
- Tools and materials needed
- Cycle time targets
Visual Scheduling & Boards
Integrated displays that show:
- Daily production targets
- Actual vs. planned progress
- Material availability status
- Problem alerts and resolution
- Production sequence and priorities
Visual Inventory
Count-free systems using:
- Min-max markers
- Kanban cards and signals
- Color-coded zones
- FIFO lanes
Production Planning & Control
LFB defines the physical flow; production planning and control align schedules and capacities to that physical reality.
Production Planning Guidance
We help you establish robust planning processes:
- Master production scheduling
- Capacity planning and takt time calculation
- Line balancing and workload leveling
- Batch size optimization
- Changeover reduction strategies
- Planning rhythm establishment (daily, weekly, monthly)
Performance Measurement
Setting up the right metrics and tracking systems:
- OEE (Overall Equipment Effectiveness)
- Cycle time and throughput monitoring
- Quality metrics (FTY, FPY, PPM)
- Inventory turns and WIP tracking
- On-time delivery performance
- Visual metric displays and dashboards
Supply Chain Optimization
Your supply chain must follow the new takt and material routes defined by LFB; we help you realign it.
Supplier Integration
Connecting suppliers to your new production rhythm:
- Delivery frequency optimization
- Packaging and presentation standards
- Pull signal implementation (Kanban, VMI)
- Supplier performance metrics
Inventory Strategy
Right-sizing inventory for your optimized flow:
- Safety stock calculations
- Reorder point determination
- Economic order quantity (EOQ) analysis
- Consignment and vendor-managed inventory options
Logistics Optimization
Streamlining inbound and outbound logistics:
- Receiving and shipping procedures
- Milk-run and route optimization
- Cross-docking opportunities
- Transportation mode selection
Data, Analysis, and Training
Post‑commissioning support is designed to build your internal capability to sustain and improve on the LFB baseline
Data Collection Systems
Setting up simple, effective data capture:
- Production count tracking
- Downtime and delay recording
- Quality defect logging
- Material consumption tracking
- Manual vs. automated collection strategy
Analysis & Problem-Solving
Turning data into actionable improvements:
- Pareto analysis of losses
- Root cause analysis methods
- Trend identification
- Corrective action tracking
- Continuous improvement project prioritization
Training & Knowledge Transfer
Building internal capability for sustained success
Operator Training
- New layout orientation
- Standard work instruction
- Quality standards
- Visual management use
Supervisor Development
- Production management
- Problem-solving tools
- Team leadership
- Continuous improvement
Management Coaching
- Performance review systems
- Strategic planning
- Change management
- Culture building
Stabilize, Ramp Up, and Continuously Improve
Our post-commissioning support helps your team achieve operational excellence in your LFB-designed facility. From stabilization to continuous improvement.