Context: A major manufacturing site had been pushed well beyond its original design point. Output had grown materially, but layout, material flow, labour model and safety arrangements had not kept pace.

Challenge: The operation was carrying high labour dependence, fragmented flow, excessive movement, weak peak agility and rising compliance and safety risk.

Role: Played a lead role in redesigning the operating footprint, focusing on automation, simpler flow, safer movement, better segregation, improved line integration and a more scalable future-state model.

Outcome: The redesigned footprint created a route to a safer and more scalable operation, with future-state capacity of 600m units, headcount reduction from 2,900 to 1,800, a reduction from 80+ lines to fewer than 30, and internal movement cut by more than 50%.