Greenfield Lean Plant Layout Design and Implementation


Application of key management tools and process

Plant Layout, Industrial Engineering Methods Improvement, Factory Master Plan

Problem State

Manufacturing company specialized in extruded cup manufacturing business had invested on equipments without assessing the capacity utilization and laid out the layout in adhoc manner which resulted into unnecessary movements , complicated planning process and low manpower productivity. The company was looking for new location to put up a plant with existing layout.

Solution State

  • Studied machine utilization pattern and assessed capacity
  • With proper Factory Master Plan , identified right equipment investment
  • Designed Lean Plant Layout with right sized equipments and simple FLOW
  • Recommended the new production planning process to improve delivery and productivity


  • Two excess machines pulled out from the line and used for future growth
  • Two excess machines pulled out from the line and used for future growth
  • supervisory manpower productivity by 50 %
  • One
  • Two

“Winning Minds” has helped us in building a culture of management by numbers from top down bottom. This has given us insight in to the operations, enabling us to clearly define goals at every level. Setting of the goals and the targeted actions has enhanced the operational efficiency and business growth over 30 %.

J S R K Prasad
CEO, Better Castings, Vijayawada
Success Stories