Facility Layout
espi partnered with FMI to design and implement a new facility layout that improved material flow, supported production growth, and enabled a smooth transition with minimal operational disruption.
Client Overview
Industry : Manufacturing – Consumer Products
FMI partnered with espi to support the selection, design, and transition to a new production facility. The engagement focused on developing a facility layout that supported material flow, storage requirements, and future growth while ensuring a smooth transition with minimal disruption to ongoing operations.
FMI’s objectives were to select a site for a new production facility, design a layout that properly supported material flows and storage needs, and create a transition plan that would allow production to continue with minimal disruption. The organization also sought to ensure the new facility could support anticipated growth and operational expansion.
The Challenge
As FMI prepared to relocate operations, leadership faced several challenges related to facility selection, layout design, and transition planning. The new facility needed to support efficient production flows, safely accommodate flammable and regulated materials, and provide adequate space for finished goods, picking, and packing operations. At the same time, FMI needed a clear plan to move equipment and product without disrupting production or customer fulfillment.
The Solution
espi worked closely with FMI to manage the facility planning and transition process. Key activities included:
Selecting a new warehouse that required renovation and identifying a general contractor to support required changes
Overseeing the construction and renovation process to align with operational needs
Developing a facility layout that organized production into key areas, including bulk fragrances, lotions and creams, and flammable products
Designing a finished goods area with dedicated picking and packing locations to support order fulfillment
Creating a detailed move plan outlining when equipment and product would be relocated to the new facility
This structured approach ensured the new facility was operationally sound and ready to support production from day one.
Realized Benefits
As a result of the engagement, FMI achieved:
Selection of a larger, better-located facility
A well-designed physical layout aligned with production and storage requirements
Successful management of the facility renovation and transition
A smooth move and a 24-hour start-up at the new facility
A facility positioned to support future growth and increased production demand
About espi
espi partners with manufacturers to design and implement facility layouts that support efficient operations, safe material handling, and long-term growth. With deep manufacturing expertise and a practical, execution-focused approach, espi helps organizations transition facilities with confidence and minimal disruption.
