Lean Facility Layout Case Studies

TXM Lean Case Study – Lean Production System Enables Manufacturer to Double Revenue
TXM helped this truck parts manufacturer double revenue after the 2008 GFC. Read how a Lean Production System was implemented...
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TXM Lean Case Study – Multi Site Packaging Supplier Lean Transformation
The Challenge Our client is the leading supplier of packaging to global electronics manufacturers and subcontractors who...
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Green Manufacturing Case Study in Lean Manufacturing: Automotive Green Plant
The Challenge This lean manufacturing case study focuses on a new green plant. The client, Futuris is a global leading manufacturer...
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TXM Lean Case Study – Implementing Lean to Meet the Challenge of Sales Surge
The Challenge Taizhou Henry Technologies is a leading manufacturer of industrial refrigeration components. Its sales grew...
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TXM Lean Case Study – Funwick Manufacturing Lean Improvements
The Challenge Funwick Manufacturing is a successful private company focused on manufacturing high quality products for global...
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TXM Lean Case Study – Increasing Sales Growth by 100% for SME
The Challenge The popularity of our client’s products presented opportunities for them to expand their market in Australia...
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TXM Lean Case Study – Lean Processes Deliver 80% Reduction in Order Lead Time
The Challenge Despite its rural location, Larnec Doors has undergone healthy growth since its inception but recently has...
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TXM Lean Case Study – ATCO Structures and Logistics
Applying Lean principles right from the start of a new facility maximises the benefits. In this case study video, the TXM...
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TXM Lean Case Study – Sykes Racing – Customised Lean Manufacturing
Sykes Racing Lean Case Study is one of the the most ambitious lean transformation TXM has ever been involved in. In this...
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TXM Lean Case Study – MacNaught Lean Manufacturing Transformation
Read this case study to learn how MacNaught a manufacturer complex engineered lubrication products for global markets achieved...
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TXM Lean Case Study – Roband Food Service Equipment
In this Lean Plant Layout Case Study learn how a new Lean Layout designed with TXM lead to major improvements for food...
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TXM Lean Case Study – Branach Manufacturing
Branach Manufacturing is perhaps the best Lean Transformation we have seen in a Small or Medium Sized Enterprise (SME). Branach...
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TXM Lean Case Study – Lean Transformation at a Small Manufacturer
THE CHALLENGE Following the Post-Glover acquisition in 2009 half of the business was relocated to a new site. The resistor...
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TXM Lean Case Study – Redesigned Processes at Agilent
The Challenge A global leader in sophisticated equipment for scientific applications, our client was facing major challenges....
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TXM Lean Case Study – Sykes Racing – An Olympic Success Story
The Challenge Back in pre-GFC 2008, world leading Rowing Boat Manufacturer, Sykes Racing was spread across several small...
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Lean Technology in Facility Layout

Lean principles are the right solution, whether you are setting up a new factory, moving into a new one, or just changing the layout of your current facility. TXM’s solution for factory layout puts everything into consideration to produce the flow you desire within your facility when handling raw materials, work in process (WIP), finished product, consumables, people movement, information, and waste.

Lean Facility Layout Case Studies

TMX has worked with and transformed business’ facility layout, yielding remarkable results as shown in the cases studies below:

Fortress Systems Pty. Ltd

The Melbourne-based resistors manufacturer relocated half their business to a new facility, occupying more space than they needed. Their plant plan was poor, lacking a clear production flow. Productivity was poor, and the plant was disorganised.

TXM implemented a factory layout that reduced lead times from 16-18 weeks to 10-12 weeks. The layout also improved space utilisation, reducing one production cell from 25m2 to 1.5m2.

Heavy Truck Manufacturer –Improved Layout and Reduced Lead Times

The client was a heavy truck manufacturer who was enjoying growth after recovering from the 2009-2009 financial crisis, but space was becoming a limiting factor. Long lead times in folding, welding, and assembly were also an issue. TMX improved the client’s facility layout, saving around 1000m2 of space for an additional production cell.

A Global Leading Packaging Supplier

The client giant packaging supplier was struggling with long lead times and poor quality and supply requirements that translated into excess WIP, low productivity, and high customer returns. Upon the implementation of TMX lean facility layout and enterprise principles, the client realised a remarkable improvement. Finished goods inventory was down 32%, lead times reduced by 28%, saving 44% of plant space, 75% reduction in monthly backlogs, and 25% reduction in quality defects and rejects.

High Technology Manufacturer

Growth and competition present challenges in increasing output and reducing cost; this is what the client was going through. TXM was able to redesign the client’s production line to reduce: final test time by 80%, packaging time by 90%, sub-assembly production time by over 50%, production lead time and WIP inventory by 75%.

Work With the Best

Lean facility layout principles from us TXM Lean Solutions can help transform your factory tremendously. We tailor our solutions to meet your specific needs. You’ll save on space, boost productivity, reduce lead times, lower inventory, and improve quality.

Please contact us today and start the process of transforming your business.