Created Additional Production Capacity in Plant to Avoid Manufacturing Footprint Expansion

Challenge

A packaging manufacturer needed a plan to support rapid business expansion in the Southwest while its existing manufacturing plant was approaching capacity.

Approach

Our production expansion and plant layout evaluation led to a SKU level capacity model which considered production assets, geographic regions, inbound material needs, finished goods transfers, customer wins, and expected sales growth. As a result, the company was able to support growth objectives with its existing footprint through a series of plant operational improvements. The company avoided $10M+ in expected CAPEX to stand up a new plant and the ensuing carbon footprint by 7,800 tons CO₂/year.