Factory Plant Layout Design Services

Make Your Plant More Efficient

  • 30% Additional Space Efficiency
  • 10% Reduction in Manufacturing Cost, FIFO
  • 20% Reduction in RM< WIP,FG

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    Area Covered

    1,35,63,250 Sq Ft

    Area Optimised

    40,68,975 Sq Ft

    Plant layout design is the methodical arrangement of equipment, procedures, and services inside a manufacturing facility. The primary goal is to optimize overall Space Efficiency while simultaneously producing the highest quality output in order to maximize production efficiency. This covers every aspect of creating an economical and effective working environment for a Manufacturing Factory Layout Plan, also known as a Factory Plant Layout Design Services.

    Tetrahedron has wide range of experience in setting up 100+ Greenfield Plant Layout Projects (New Plant Set-Up) and 150+ Brownfield Plant Layout Projects (Space Creation in Existing Infrastructure with & without major infrastructural changes), helps manufacturing companies in implementing Good Manufacturing Practices (GMP), required to achieve the following 10 business objectives.

    • Improvement in Floor Space Utilization Efficiency (Production Area versus Total Area) 
    • Reduction in Cost of Material Transportation
    • Improvement in Capacity Utilization
    • Improvement on OLE (Overall Labour Efficiency)
    • Improve Flow of Material and Reduce Line Stops
    • Develop Flexibility for Die Change, Set-Up Change, Product Change
    • Enhance Ease of Operation Management
    • Improve Health, Safety, and Environment
    • Refine Ease of Maintenance of Complex Machines
    • Reduction in Inventory, Work In Progress, and Finished Goods

    Benefits of Factory Plant Layout Design

    space creation

    30% Space Creation In Existing Infrastructure

    distance travel

    20% Reduction in Distance Travel by Material


    100% Workplace Safety Based Plant Layout

    machine setup

    50% Reduction in Machine Set-Up & Change Over Time


    10% Reduction in Inventory Level and Inventory Space

    material handling

    20% Reduction in Material Handling Equipment Usage

    zero line

    Zero Line Stop Due to Material Unavailability

    visual factory

    Visual Factory For All Activities and Process

    proper lighting

    Proper Lighting & Usage of Natural Light

    Prepare For Future Changes and Enablers

    Lean Plant Layout Development Approach

    When developing a Lean Plant Layout design, meticulous planning and careful analysis are required to increase efficiency. Before starting, we have to collect all the requirements and thoroughly understand the production process. So we have a proven approach consisting 8 steps that will help to make the plant layout design conceptual with optimized output, reduce expenses, and foster a secure work environment.

    Plant Layout 8 Steps Detailed Approach

    Advantages of Tetrahedron's Lean Layout Approach

    A Plant / Factory layout design should be valid for at least 5 Yrs.

    Factory Layout Design is a critical investment for any manufacturing company, and a flow-focused – effective layout impacts business performances and profitability. Once a layout is frozen it’s almost impossible or very cost-intensive to change the layout especially after the civil works are completed.

    Tetrahedron considers these facts and tries to create multiple (more than 10) simulation wherein the client can select the best possible layout with existing business requirements as well as all possible future plans.

    3D Plant Layout

    Visualize how 3D simulations created by Tetrahedron works as a perfect bridge between the Concept Level Layout and Final Post Construction layout. Tetrahedron uses multiple software for layout design and 3D simulations, that helps the clients to visualize how the future plant is going to look like post-implementation of Lean Layout with (GMP) Good Manufacturing Practices.

    Business & Operational Performance Planning

    Tetrahedron takes into consideration lean manufacturing practices and design layouts that will help to –

    (1) Improve Line Balancing

    (2) Improve Manpower Utilization

    (3) Plan and Optimise Inventory

    (4) Calculate Manpower Requirements

    (5) Reduce Material Handling Equipment Requirement

    (6) Improve Space Efficiency

    (7) Good Manufacturing Practices

    Advantages of Plant Layout

    Serving These Manufacturing Industries

    Plant Layout Industry

    Case Study

    Lean Layout In Fettling Operation

          (Leading Global Automotive Part Manufacturer)


    Before Tetrahedron–

    • Operating as a batch process fettling operation leading to huge  WIPs 
    • Frequent delivery failures due to unavailability of finished goods.


    Tetrahedron conducted a Time & Motion Study for Shot-blasting to painting operation of the fettling line with a target to develop a Lean Line with 5 years capacity projection. The result achieved in 6 months.


    • 3 Shifts (24 Hrs) operation reduced to 19 Hrs
    • Line Balancing Implemented – Sequential Flow of Goods, FIFO
    • Line formation with exact manpower requirement with projections
    • Identified 20+ Simple Automation
    • Multiple Operation by single workman by formation improvement
    • WIP reduced by 50%

    Green Field Layout Of Glazing Division

     (India’s Largest UPVC  Manufacturer (Bhiwadi))


    Before Tetrahedron-

    • High Cost due to High Manual Manufacturing
    • Low Productivity  due to non standardized product
    • High WIP because of Material Handling
    • High Manual Packaging leading to high labor Costs


    Tetrahedron studied the entire production line and helped to identify at least 43 opportunities to implement automation. With this in mind, 17 high-impact projects were taken on.


    • 36% Manpower Reduction
    • Ideation and Implementation of end to end Material Handling
    • Material Handling breakages reduced by 70%
    • 40% Line Productivity Enhancement


    Our Clients

    Hero company logo

    Merino company logo


    Romsons Company Logo

    Apollo Pipes company logo

    DFM Foods Ltd.

    Tata Electronics




    Matrix clothing company logo

    Unisol Company Logo


    Salasar Alloy And Steel


    Trina NRE

    Regal Paints


    ENCO company logo



    MTC Group

    asahi ropes company logo

    SRAPL company logo

    Stefen Electric

    Our Clients


    Can I Get multiple 3D simulations of layout according to my requirements ?

    Yes, Tetrahedron Create Multiple-3D Possible Layouts with Simulation that enables Clients to take an informed decision considering all future possibilities of Capacity Augmentation, Operational Performance, Manpower Planning, Automation and Digitization. You can also visualize How much inventory is generating in between the processes.

    Does Plant layout design also includes Safety aspects in shop floor?

    Yes, Tetrahedron Design Lean factory layout in way that also consider National building codes & Required Safety ISO, We also plan Fire Safety and Fire Exit Doors.

    What are the 4 primary plant layout methods?

    A successful factory layout design takes safety precautions, equipment placement, workflow efficiency, and space utilization into account.

    Can I get help in implementation process on site ?

    Yes, after completion of the plant layout tetrahedron will also help in implantation of the suggested layout plan start with machine marking on shop floor to implementation of machine on the floor.

    In how much time will i get Factory plant layout design?

    We usually give final Factory plant layout design in 7 to 8 weeks. It also depends upon the size of the plant , Complexity of the production processes, in that case we take 2-3 more weeks.

    How do I optimize factory plant layout design?

    You can optimize your Factory plant layout design by effectively utilisation of vertical and horizontal space, WIP Inventory reduction, Material and Manpower movement reduction on shop floor, Better Natural lighting and ventilation.

    What is Lean Plant Layout ?

    Lean Layout is the ideas and techniques for total elimination of waste. The goal of Lean Layout is to increase efficiency, productivity and flexibility in the production process for full utilisation of Cubic space, Machinery, Manpower to increase Productivity and Profit with Zero Waste.

    What is the best layout for lean?

    It depends on the type of manufacturing company, product, material used ,machinery and many more factors. Our experts guide you according to your company and suggest best layout for you.

    What are the impact of lean waste on manufacturing company?

    Because of Lean Waste company can faces problems like Delivery Inconsistencies, excessive material flow, space for inventory, over production, over processing , Employee Dissatisfaction and many more.

    What methods can I use to increase production capacity of manufacturing plant layout design?

    By lean plant layout you can increase productivity because lean plant layout decrease machine change over time, waiting of workers, over processing, over production, distance travel by material and manpower and increase overall productivity and also save energy cost .

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