Layout, lean & capacity
Plant layout design and lean process optimisation
More output from the same floor, people and machines. We study how your plant actually runs, redesign layout and flow, balance lines and implement the changes with your team — not a report that sits on a shelf.
At a glance
- Studies
- Time & motion, line balancing, capacity, flow
- Outputs
- New layout, balanced stations, standard work
- Methods
- Lean, 5S, SMED, value-stream mapping
- Timeline
- Indicative 2–8 weeks study; phased implementation
- Measured by
- Output per shift, WIP, travel, floor space
Overview
Find the capacity you have already paid for
Before investing in a new line or a new building, most plants have capacity hidden in the current one: unbalanced stations, operators walking for parts, WIP piling up between operations, long changeovers, and layouts that grew one machine at a time.
We measure first — cycle times, walking distances, waiting, changeover and downtime — and map the value stream. Then we redesign layout and flow, rebalance work across stations, and set up standard work, part presentation and visual controls.
Where the study shows that new equipment is needed, we can design and build it. Where it does not, we help you implement the changes on the floor and measure the result against the baseline.
What we build
Studies and improvements we deliver
Plant layout design
New layouts or re-layouts of shops and plants with material flow, aisles, storage and expansion planning.
Time & motion study
Stopwatch and video-based studies to set standard times and remove non-value-adding motion.
Line balancing
Redistributing work elements to hit takt time with fewer bottlenecks and less idle time.
Capacity assessment
Machine and line capacity against demand — where the real constraint is and what it costs you.
Value-stream mapping
Current- and future-state maps showing lead time, inventory and flow improvements.
5S & visual management
Workplace organisation, floor marking, shadow boards and visual controls that last.
SMED / changeover reduction
Moving internal setup to external, quick-change fixtures and standard changeover work.
Material presentation & kitting
Line-side racks, kitting trolleys and supermarkets that stop operators searching for parts.
Standard work & SOPs
Standard work sheets, SOPs and training aligned to the improved process.
Technical
Plant Layout & Process Optimisation — applications, specifications and deliverables
The same three-part technical structure on every solution page, so engineering and procurement can compare scopes without reading marketing copy.
Applications
What it is applied to
- Plants running out of floor space
- Lines that cannot reach rated output
- High WIP and long internal lead times
- Moving to a new building or adding a line
- Preparing for a new customer's audit
- Reducing overtime and dependence on specific operators
Not listed? Describe the operation — most scopes we quote are variations on these.
Typical specifications
What we engineer to
- Study boundary
- Single cell, line, shop or whole plant
- Data captured
- Cycle times, walking distance, WIP, changeover, downtime, space use
- Takt basis
- Target output per shift against available working time
- Line balance target
- Station loading balanced to within a stated percentage of takt
- Layout options
- Two or three costed options compared on flow, space and capital
- Material presentation
- Line-side racks, kitting, supermarket or direct feed
- Expansion allowance
- Future capacity held explicitly in the layout
- Implementation
- Study only, or study plus supervised implementation
- Measurement
- Before/after output, labour, WIP, lead time and floor space
- Indicative timeline
- 2–8 weeks for the study, depending on data collection
Indicative ranges. Final specifications are fixed against your part and volume at design freeze.
Engineering deliverables
Documents you receive
- Current-state layout and value-stream map
- Time-study data, capacity model and bottleneck analysis
- Proposed layout options in AutoCAD (DWG and PDF), compared and costed
- Line balance and yamazumi chart with manpower plan
- Material flow and presentation plan
- Equipment and utility schedule for the proposed layout
- Phased implementation plan sequenced around production
- Standard work sheets and before/after measurement report
Programs and drawings are handed over, so your team is never dependent on us for a change.
Engineering scope
How each element is engineered
The design decisions behind the specification above.
| Data captured | Cycle times, walking distance, WIP, changeover time, downtime, space utilisation |
|---|---|
| Tools | Time study, video analysis, spaghetti diagrams, value-stream maps, simulation where useful |
| Layout deliverables | AutoCAD layouts (current and proposed), flow diagrams, phasing plan |
| Implementation | Hands-on with your team — re-layout, fixtures, racks, standard work |
| Results measured | Output per shift, labour productivity, WIP, lead time, floor space |
| Engagement | Fixed-scope study, or study plus implementation |
Handover
What you receive
Every layout study project closes with a documented handover — not just a machine on the floor.
- Current-state data and value-stream map
- Bottleneck and capacity analysis
- Layout options with pros and cons
- Line balance and standard work sheets
- Implementation plan phased around production
- Before/after measurement report
- Training for supervisors and operators
Execution
How we execute a layout and optimisation project
One project manager, stage gates you sign off, and no hand-offs between vendors.
Observe
Gemba walks, time studies and data collection across shifts.
→ Current-state baseline
Analyse
Bottleneck, waste, flow and capacity analysis.
→ Improvement options
Design
New layout, line balance, part presentation and standard work.
→ Approved future state
Implement
Re-layout, fixtures, racks and training — phased around production.
→ Changes live
Measure
Before/after measurement against the baseline.
→ Results report
Sustain
Audits, standard work and follow-up support.
→ Sustainment plan
Applications
Where it is used
- Plants running out of floor space
- Lines that cannot reach rated output
- High WIP and long internal lead times
- Moving to a new building or adding a line
- Preparing for a new customer's audit
- Reducing overtime and dependence on specific operators
Industries we serve
Why Mecwerx
Why manufacturers choose us for this
We measure before we redesign
Recommendations come from time studies and flow data on your floor, not from generic templates.
Implementation, not just a report
We stay to move equipment, build racks and fixtures, and train people.
Engineering depth
When the answer is new equipment, we can design and build it — one partner from study to solution.
Measured results
Every project closes with a before/after comparison against the baseline.
Quotation checklist
What we need for an accurate layout study quote
Send what you have. Missing details are fine — we will fill the gaps during the technical discussion.
- Current layout drawing (even a rough sketch)
- Products, volumes and shift pattern
- Current output and target output
- Main problems observed
- Constraints — building, budget, timelines
- Planned changes such as new products or expansion
FAQ
Plant Layout & Process Optimisation: common questions
What is included in a plant layout study?
Data collection on your floor, current-state layout and flow analysis, bottleneck identification, two or more layout options with material flow, a recommended layout and a phased implementation plan.
How long does a time and motion study take?
A focused study on one line typically needs one to two weeks of floor time plus analysis. Plant-wide studies take longer and are phased.
Can you improve output without buying new machines?
Often, yes. Line balancing, layout changes, part presentation, changeover reduction and standard work frequently recover significant capacity. The study shows how much before you commit capital.
Do you help implement the changes?
Yes. We plan and implement the changes with your team — equipment relocation, racks, fixtures, standard work and training — phased around production.
Can you design the layout for a new plant?
Yes. For new plants we develop the layout from your process and volumes and hand over the data your civil and MEP contractors need. Full execution is covered under turnkey plant setup.
Related
Related solutions
Turnkey Plant Setup
Greenfield and brownfield plants — layout, utilities, equipment, lines and commissioning under one contract.
Learn moreAssembly Lines
Takt-balanced manual, semi-automatic and automated lines with conveyors, error-proofing and traceability.
Learn moreWorkstations, Racks & Trolleys
Ergonomic and ESD workstations, pipe-and-joint flow racks, kitting trolleys and tool boards.
Learn moreStart a project
Hand over your production challenge.
Tell us what the line has to produce, where, and by when. We will come back with a scoped approach, a realistic timeline and the questions that matter — usually after a site visit or a drawing review.
- +91 85959 55435 · Mon–Sat, 09:00–18:00
- WhatsApp an engineer
- info@mecwerx.com
- Detailed RFQ with drawings (PDF, DWG, STEP)