What We Do
From greenfield to
turnkey, engineered
for flow.
Lean Facility Design is delivered as modular engagements
— from a core lean blueprint to
a fully engineered, turnkey factory.
Faber Infinite · Lean Facility Design
15 engineered steps.
Where Most Factory Layouts Quietly Bleed Money
The Hidden Cost of Poor Layouts
30%+ of operating cost is locked inside avoidable movement, congestion and rework; invisible on the P&L, but visible on the shop floor.*Faber Infinite Research
Tangled Material Flow
Material crisscrosses the plant instead of moving linearly.
Overstocked, Congested Stores
Excess WIP and finished goods hidden across the shopfloor.
Excessive Travel Distance
Operators and forklifts cover kilometers daily - most of it waste.
Poor Space Utilization
Floor area lost to old material, scrap and unplanned WIP buffers.
Bottlenecks & Long Lead Times
Capacity ceilings nobody mapped before the lines were laid.
Safety & Supervision Gaps
Blocked sightlines, unsafe forklift paths, audit risk.
What Poor Layouts Cost Manufacturers
Material crisscrosses the plant instead of moving linearly.
Operators and forklifts cover kilometers daily, most of it is waste.
Excess RM, WIP and FG hidden across the shopfloor.
Delays arising from prolonged process lead times.
Capacity nobody mapped before the lines were laid.
Locked in machines, MHEs, and warehouse.
Typical Steps: Lean Facility Design
A 15-step framework structured into
three phases - Planning, Flow Integration and Execution Readiness.
Phase 1
Training and Orientation
Product, Process, Quantity Analysis (PPQ)
Value Stream Identification
Value Stream Mapping (CSM, FSM)
Flow Management
Phase 2
Capacity Planning and Ramp-up Plan
Equipment Planning Guidelines
Manpower Planning Guidelines
Supply Chain Design
Phase 3
Flow Supermarket & Line Side Design
Conceptual Material Handling Design
Layout Design
Visual Management Guidelines
Risk Assessment
Project Rollout Plan
Design Your Factory of the Future
Lean Facility Design is delivered in four modules - from the core lean layout blueprint to a turnkey, fully engineered factory.
LFD Core
The essential lean layout blueprint
Value stream mapping, flow design, layout options and an execution roadmap - the foundation of a lean factory.
LFD Smart
Blueprint + planning & 2D CAD
Adds PPQ analysis, capacity & manpower planning, equipment selection, inventory frameworks and 2D AutoCAD drawings.
LFD NextGen
Digitally validated factory design
Adds 3D modelling, Industry 4.0 readiness, automation conceptualization and critical decision-point analysis.
LFD NextGen+
Turnkey factory of the future
Everything, plus 3D walkthroughs, simulation, complete engineering & infrastructure support and end-to-end PMC.
| Scope of Work & Deliverables | LFD Core | LFD Smart | LFD NextGen | LFD NextGen+ |
|---|---|---|---|---|
| Section 1: Lean Facility Design & Operational Blueprint | ||||
| Capability Development & Analysis | ||||
| Training & orientation of project team members | ||||
| Product–Process Quantity Analysis (PPQ) | - | |||
| Value Stream Mapping (CSM & FSM), Spaghetti Diagrams & Transportation Index | ||||
| Future-State Design & Flow Management | ||||
| Flow design & line-side optimization | ||||
| Supply chain and supermarket design | ||||
| Planning & Resource Optimization | ||||
| Capacity planning & ramp-up strategy | - | |||
| Manpower requirement planning | - | |||
| Equipment selection guidelines | - | |||
| Layout, Safety & Workplace Efficiency | ||||
| World class, efficient layout design options | ||||
| Ergonomic and safety guidelines | - | |||
| Visual factory design standards | - | |||
| Material & Inventory Optimization | ||||
| Inventory optimization through customized frameworks (zero shortage, no overstocking) | - | |||
| Improvement & Decision Support | ||||
| Action plan for key process improvements | ||||
| Identification of critical decision points | - | - | ||
| Execution Roadmap and Deliverables | ||||
| Comprehensive executive report covering objectives, observations, challenges, actions taken, quantified benefits, and detailed implementation roadmap | ||||
| Section 2: Design Visualization & Simulation Suite | ||||
| 2D AutoCAD drawings | - | |||
| 3D modelling (AutoCAD) | - | - | ||
| Section 3: Strategic Enhancements & Value Additions | ||||
| Documentation & knowledge transfer | ||||
| Industry 4.0 Readiness Assessment | - | - | ||
| Risk mitigation assessment | - | |||
| 5 copies of the exclusive Lean Facility Design (LFD) book | ||||
Peripheral Offerings (on request)
Your Complete Ecosystem for Plant Development & Transformation
| Category | Add-on |
|---|---|
| Visualization & Simulation | 3D walkthrough video for spatial understanding |
| Simulation models for flow and operational validation | |
| Strategic Enhancements | Automation conceptualization & implementation support |
| ESG guidelines integration | |
| Inputs from Vastu consultant (if required) | |
| Civil, Structural & Architectural Support | Architectural planning & site development |
| Structural engineering | |
| Utilities & Technical Systems | Electrical systems |
| Plumbing & drainage (Public Health Engineering) | |
| Fire protection & detection systems | |
| HVAC (air conditioning & ventilation) | |
| Air, gas & water systems | |
| STP & ETP systems | |
| Industrial Infrastructure | Crane planning |
| Machine shifting & MEP integration | |
| Sustainability & Environment | Green building design (IGBC Platinum standards) |
| Landscaping | |
| Project Management & Implementation Support | PMC (Project Management Consulting) support |
| End-to-end implementation support | |
| Resource planning & governance framework | |
| Post-audit support |
How We Work With You
Robust Engagement Structure
Every engagement is layered with senior oversight, dedicated delivery leadership and independent quality assurance - so results don't depend on any one individual.
Client
Client Engagement Advisor
30+ years of exp
Business Head
~20 years of exp
Client Engagement Manager
~10+ years of exp
Supported throughout by
Business Alliances
Delivery Team
Body of Knowledge
Quality AssuranceEngineering the Future Through 3D Visualization
Walk Your Future Factory Before It Is Built
From block layouts to immersive 3D walkthroughs and simulation models - validate flow, space and capacity decisions before committing a single rupee of CAPEX.
Block Layout
Macro flow optimization - zoning, adjacency and material flow direction decided before a single wall is drawn.
Detailed Layout
Workstation-level design - every machine, rack, gangway and utility positioned for flow and safety.
3D Walkthrough
Immersive validation - walk your future factory in 3D, catch issues and win stakeholder buy-in before construction.
Not sure which module fits your project?
Talk to our Lean Facility Designexperts — we'll assess your greenfield or brownfield project and recommend the right scope.
Book Free Consultation