Jackson Productivity Research Inc.
Productivity is our middle name

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Plant Layout and Facility Design
The arrangement of people, materials and machines is at the very heart of business productivity;
in an organization of any size;
engaged in just about any endeavor.

Perhaps your challenge is similar to these examples from our experience:

Relieve a jam-packed plant. This charter usually requires both short and long-term solutions, perhaps a phased approach to keep operating during rearrangement. A sinkhole on this property didn't help.

Create better flow, or more output, with today's product mix. The latest project was a complex pick and ship warehouse, with product up to 40 foot steel beams,plate, bars, tubes. The object was to arrange stock in order to cut crane delay and length of moves. Time study was a major tool of this project.

Revise layout, add output and capacity, facilitate new products. A Naval Air Station prototype facility required fast reaction from its flexible high tech equipment, although some facilities went back to bi-plane days. Some operations such as prototype shops apply a pack rat mentality to cut cycle length compared to just-in-time.

Rearrange to cut through a wasteful "spaghetti" flow. Good flow is routinely a prime objective for all layout projects, along with space utilization. However the vaunted Amazon warehouses only use eight feet or so of height, and flow is very irregular. The solution is to layout according to the situation, one size does not fit all.

Layout and start up a new operation, instead of or in addition to; large or small; locally or in a new community. At least seven JPR projects involved moving an operation into a distant existing facility, seems always to require a short time frame.

Acquire or consolidate operations or facilities; shut down obsolescent plants, upgrade buildings and equipment. We go through facility planning steps first, then layout comes into the picture as we arrange, and fit in, the chosen process. Watch out for the community permitting process, and the time required.

Find a site for a new facility, with plentiful qualified labor and low operating and distribution costs. Our approach is to quantify in advance the expected acquisition and operating costs in candidate communities, and define what suitable property is available for the short list. (But find out early, where does the boss want to be?)

JPR can assist you to use layout effectively within your facility, to achieve your particular goals, budget, timetable. We are experienced, objective, and quick. We have the time and ability that perhaps your team doesn't have right now. We can guide, train, or perform the layout design.

With today's internet tools, with conferencing, video clips, and files and drawings on .pdf, JPR has provided remote layout service to clients quickly, effectively and without the need to travel. And much of site search, for a new location, is routinely performed on line.

Please call Jack Greene at 843-422-1298, or e-mail at

Productivity and Industrial Engineering Books

These books offer practical strategic guidance to plan and tailor projects to meet your objectives. Chapters explain what and why, with detailed hands-on instructions, to generate accurate and objective results, quickly and smoothly within the physical and organizational constraints of the operation. Chapters improve project management by highlighting which practices to utilize and which missteps to avoid, and extend the technical capabilities of your staff.

The Industrial Engineering book includes the contents of Time and Motion Study, Layout, and Cost Reduction; but not Construction Piece Rates . Please click a cover for contents. Click here for the Kindle version of Plant Layout and Facility Planning


JPR is a boutique consultancy that applies layout principles expertly and rapidly, in manufacturing and service industries. JPR's value is to select and utilize the appropriate productivity principles and tools, tailored to the client's specific objectives, timing, and budget.

In all of these challenges, a good layout is part of the answer. To improve flow and utilize space, let me suggest two axioms that constantly apply.

1. Layout is equally as useful in the office, the lab, the shop, customer service, distribution and the warehouse as on a production floor.

2. Layout projects are not all the same, because no two facilities or processes are the same. There will not be a template on the web, or a standard floor plan, that matches your situation. Since you desire a competitive advantage, you won't want a generic solution anyway, you will want a layout tailored for your particular building, equipment, process. To create an effective layout for your circumstances, JPR can perform a project, shepherd your staff, or tailor services to supplement client resources.

E-mail Jack Greene at or call 843-422-1298, to ask about layout There is neither charge nor obligation for discussions..

Consulting Deliverables Plant layouts tend to be infrequent, designed to catch up to changes in equipment, products, volumes, and flow. Get it right, the next one may not occur for a while.

Your organization's specific goals will be unique, and on a consulting assignment JPR would apply those from the following concepts that will contribute to your specific objectives, because all layout projects are not the same.

For an effective new layout, first pull out all of the waste movement, all unnecessary material handling.

Create plans that satisfy not only current but also future space demands.

Place work stations and inventory to amplify their interactions

Arrange for simple, short and direct material flow paths.

The keyword is utilization; of space of course but also of equipment where it can serve multiple products.

When you include all the stake holders in the development process, the resulting layout will very likely be more well suited to real conditions, and you'll put it into effect more smoothly.

Create layouts to accommodate new technology, additional products or volume. Apply productivity principles to create an effective arrangement, to minimize space constraints.

It is very common to execute a relocation with a "checkers" game, a series of sequential moves.

Office layouts are a special case because they usually are quite visible, and affect both clients and executives.

What's Next? JPR can help you to use layout principles, within your organization, to achieve your particular goals. We are experienced, objective, and quick. We have the time and ability that perhaps your team doesn't have right now. We can guide, train, lead or perform the layout project.

One size does not fit all, when it comes to layout. JPR does not offer the "buzz-word of the month", but chooses from time-tested techniques to meet client circumstances and objectives.

Take the next step; call JPR to discuss the most appropriate solutions for your unique circumstances, timetable and budget. There is no cost nor obligation for preliminary discussions. E-mail Jack Greene at or call 843-422-1298.

Layout Articles We have authored an on-line Management and Productivity series, and specialized web pages. Please touch the link for further reading

For Warehouse Layout, web page Touch to read

For Shop Layout, web page Touch to read

For Productivity Series article on specific shop layout issues how to resolve them Touch to read

For Merger or Consolidation layout, web page Touch to read

Article, Consolidate, or Merge Facilities Touch to read

Article, Layout, Factory Design, Floor Plan Touch to read

Article, Relocate a Facility Touch to read

Free Layout Guide Touch to request

Contact Jack Greene today for a rapid response, at 843-422-1298 or e-mail.