Production & Process Design

Designing efficient, scalable production systems optimized for your product and volume requirements. Real factory experience.

Real Factory Experience

We've designed production lines, planned capital expenditure, eliminated bottlenecks, and optimized through KPI-driven continuous improvement.

Production readiness isn't theoretical — it requires understanding cycle times, labor content, quality gates, and material flow in real manufacturing environments.

What We Deliver

  • Production-ready line designs
  • Capacity and throughput models
  • Capital equipment plans and budgets
  • Bottleneck identification and elimination
  • Traceability and control systems

Production System Development

Production Line Design

Layout optimization, workstation design, material flow, and ergonomics for efficient, safe production.

Process Value Streams

Map current state, identify waste, design future state, and implement lean manufacturing principles.

Manufacturing Readiness

Assessment and planning to ensure smooth transition from prototype to production.

Capital Equipment Planning

Strategic equipment selection and justification aligned to volume and timeline.

Equipment Selection

  • Process capability requirements
  • Manual vs automated decision frameworks
  • Volume and flexibility trade-offs
  • Total cost of ownership analysis
  • Supplier evaluation and down-selection

Capital Planning & Budgeting

  • ROI and payback period analysis
  • Phased investment strategies
  • Risk mitigation and contingency
  • Installation and commissioning planning
  • Training and support requirements

Traceability & Control Systems

Building systems to track, monitor, and control production for quality and compliance.

Traceability Planning

Define what to track, how to track it, and how to retrieve information when needed for investigations or recalls.

Data Collection

Manual, semi-automated, or fully automated systems for capturing production data, test results, and genealogy.

Control Systems

In-line inspection, SPC monitoring, and automated reject mechanisms to prevent defects from progressing.

Capacity Planning & Optimization

Capacity Analysis

Calculate theoretical capacity, identify constraints, and model scenarios for volume changes.

  • Cycle time analysis
  • Bottleneck identification
  • Throughput modeling
  • Shift and labor planning

Bottleneck Elimination

Systematic approaches to remove constraints and increase system throughput.

  • Theory of Constraints (TOC)
  • Workload balancing
  • Parallel processing opportunities
  • Buffer and inventory optimization

KPI-Driven Optimization

Measure what matters and drive continuous improvement through data.

Efficiency Metrics

  • Overall Equipment Effectiveness (OEE)
  • Cycle time and takt time
  • Labor efficiency
  • Material utilization

Quality Metrics

  • First-pass yield (FPY)
  • Defect rates by station
  • Scrap and rework costs
  • Customer returns

Delivery Metrics

  • On-time delivery (OTD)
  • Lead time performance
  • Work-in-process (WIP) levels
  • Order fulfillment rates

Ready to design a production system that works?

Let's discuss your product, volume, and timeline — and build production capability that delivers.

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