How It Works

Client: XYZ Packaging Plant (Food & Beverage)  

Project: Packaging Line Re-Layout & Material-Flow Optimization  

Scope: Current high-touch secondary packaging operation has chronic downtime and  operator bottlenecks. 

Goal: Reduce walk distances, improve visibility to line, and prepare for future case-packer integration.  

Deliverables 

 1. Current-State Layout & Walk-Path Mapping 

• As-is layout with marked operator routes and material flows 
• Choke-point identification and downtime notes  

2. Two Concept Options 

• Option A: "Minimize footprint" – keep in current space, reconfigure stations  for flow 
• Option B: "Optimize for growth" – minor wall relocation, expanded staging  area, future case-packer prep 
• Each option: marked flows, operator walk paths, changeover-access notes,  and 1-paragraph pro/con summary  

3. Refinement Pass 

• Incorporate client feedback; combine best elements of both options into  preferred concept 
• Add maintenance access, storage allocation, and phasing notes if any  infrastructure changes needed  

4. Hand-Off Package

• Final CAD layouts (4 sheets: current state, concept options, preferred concept,  flow detail) 
• 1-page concept brief summarizing layout logic, assumptions, and  recommended next steps for detailed engineering
• Optional: 30-minute review call with client's PE firm or OEM to walk through  concept  

Timeline  

•  Week 1: Discovery, existing conditions review  
• Weeks 2–3: Concepts drafted and refined  
• Week 4: Final layouts and brief delivered 

This investment positions your detailed engineering for faster execution and fewer iterations, typically saving $5,000–$15,000+ in stamped-engineering revision cycles.  

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