Redesign and Relocation of Production Plant
- Christian Ocariz
- Sep 10, 2024
- 3 min read
The design of #production_plants is a crucial discipline focused on the optimal organization of space, workflows, and resources to maximize efficiency and productivity. An effective design can reduce costs, improve product quality, and shorten #production times.
Here, I share a challenging project where I had to relocate a factory into a space 30% smaller within record time, ensuring that operations continued without interruption and with improvements in efficiency. This project highlights the importance of strategic design and meticulous planning in achieving operational success and optimizing resource use.

According to a study by the Institute of Industrial and Systems Engineers (IISE), companies that redesign their production plants to optimize space and improve workflows can experience up to a 50% improvement in operational efficiency and a 30% reduction in operating costs.
Project Context:
The need to optimize resources and reduce operational costs led us to relocate a production plant to a new location, 30% smaller than the original. The goal was not only to move the factory but also to redesign the plant to improve operational efficiency and minimize any impact on production.
Challenges:
1. Space Reduction:
• Adapting the production plant to a significantly smaller space without compromising production capacity.
2. Record Timeframe:
• Completing the relocation and startup within a very short period to avoid disruptions in operations.
3. Employee Involvement:
• Ensuring employee participation in the design and transition to leverage their knowledge and experience.
Implemented Solution:
1. Detailed Planning:
• Conducted a thorough analysis of the new plant’s needs and constraints. Developed a detailed plan encompassing each step of the relocation, from dismantling at the old site to startup at the new location.
“Detailed planning was crucial for ensuring a smooth transition and minimizing disruptions.”
2. Efficient Layout Design:
• Redesigned the plant layout using advanced production plant design techniques. Implemented the concept of “production cells” to optimize workflow and reduce space usage.
“The layout redesign allowed us to maximize the use of available space and improve operational efficiency.”
3. Stakeholder Involvement:
• Engaged employees, from operators to managers, in the design and relocation process. Their participation was key to identifying areas for improvement and ensuring the new design met operational needs.
“Employee involvement in the design and transition was crucial to ensure that the new layout was functional and efficient.”
4. Training and Adaptation:
• Provided training for all employees on the new layout and procedures. Included practical training sessions to ensure quick adaptation to the new environment.
“Training ensured that all employees were prepared and comfortable with the new design and procedures.”
5. Continuous Monitoring and Improvement:
• Established a continuous monitoring system to assess the performance of the new layout and make adjustments as needed. This approach allowed us to quickly identify and address any issues that arose.
“Continuous monitoring allowed us to adjust and improve the layout to ensure optimal operation.”
Project Results:
• Space Reduction Achieved: Successfully relocated the plant to a space 30% smaller without losing production capacity.
• Improved Operational Efficiency: Achieved a 20% improvement in operational efficiency due to the optimized layout and implementation of the “Route of the Rabbit” concept.
• Reduced Downtime: Completed the relocation and startup in record time, minimizing production interruptions.
• Increased Employee Satisfaction: Employee involvement in the design and relocation process enhanced their commitment and job satisfaction.
The successful implementation of this project not only demonstrated the importance of an efficient plant design but also highlighted the value of involving employees in the change process. Through detailed planning and innovative design strategies, we transformed a significant challenge into an opportunity to improve operations and boost employee satisfaction.