Plant Layout Design | Manufacturing Factory Layout Plan

Make Your Plant More Space Efficient





Area Covered

1,35,63,250 Sq Ft

Area Optimised

40,68,975 Sq Ft

30% Additional Space Efficiency

20% Reduction in Material Travel

20% Reduction in RM, WIP, FG

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 (Creating space within existing infrastructure, whether through major changes or minor adjustments), helps manufacturing companies in implementing Good Manufacturing Practices (GMP).

Benefits of 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

Get a free audit of your existing plant layout for maximum efficiency and space utilisation

Lean Plant Layout Development Approach

When developing a Lean Plant Layout design, meticulous planning and careful analysis are required to increase space efficiency. Before designing, it is important to analyze the management requirements and thoroughly understand the production process. Following that, we can proceed with data collection, process mapping, and analysis. So we have a proven approach consisting 8 steps that will help to create 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 (4-5) simulation wherein the client can select the best possible layout with existing business requirements as well as all possible future plans.

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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

What is Visual Management System?

Visual Control and Visual Displays are used to visually operate a manufacturing facility called Visual Factory. Visual Management helps employees or workers to get quick information about the workplace and tasks being completed. Benefit of creating visual displays in your organization is to “Encourage workers to feel a feeling of responsibility for the workplace”. So that management can make decisions quickly based on the information.

How to create Visual Management in Manufacturing Business

In order to set up Visual Management in the manufacturing business, we have to train employees/workers, implement new solutions, and ongoing effectiveness monitoring is required. Visual Management involves strategically placing visual cues like signages, color-coded floor markings, and specified work areas to maximize productivity and safety that helps in maximizing productivity and safety.

Serving These Manufacturing Industries





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


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APLApollo Review

Hindalco Review

APAR Review

Diligent Review

Tata Electronics Review

Fenesta Review

Asahi Ropes Review

Our Clients

Hero company logo


Merino company logo

Romsons Company Logo

Apollo Pipes company logo





Matrix clothing company logo

Stefen Electric

Salasar Alloy And Steel

Tata Electronics



Regal Paints

Trina NRE




SRAPL company logo

ENCO company logo

asahi ropes company logo

Unisol Company Logo



5 by 7 Solutionns

Lotus Kitchen Redefined

Felix Schoeller

Arjan Auto

Our Clients

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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.

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 are the 4 primary plant layout methods?

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

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 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 .

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.

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.

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.

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