Designing Scalable and Efficient Production Operations
Rising SKU counts, increased customization, and labor availability challenges are placing greater demands on manufacturing, assembly, kitting, and value-added services (VAS) operations. Organizations must balance throughput, labor efficiency, space utilization, quality, and flexibility while supporting changing product mixes and customer requirements. OPSdesign Consulting helps companies design and optimize these operations to meet current demand and scale efficiently for future growth.
For more than 20 years, OPSdesign Consulting has designed manufacturing, light production, assembly, and value-added services operations across diverse industries. We begin by analyzing product characteristics, volumes, order profiles, batch sizes, and process variability. Applying “best process first” thinking and industrial engineering principles, we eliminate unnecessary handling, excess touch points, and non-value-added activities before developing layout, labor, and technology solutions.
Our team designs right-sized layouts, standardized work methods, balanced work cells or lines, and scalable workflows that align capacity, throughput, labor efficiency, and space utilization with business objectives. We focus on practical, low-risk solutions that improve productivity, accuracy, and visibility while maintaining flexibility for changing SKUs and volumes.
OPSdesign has extensive experience designing operations that integrate seamlessly with upstream supply and downstream warehousing, distribution, and fulfillment processes. We take an unbiased approach to automation and tooling, evaluating manual, mechanized, and automated alternatives to maximize return on investment while minimizing operational risk. Quality, safety, and ergonomics are embedded into every design to support consistent execution and workforce engagement.
Examples of Manufacturing, Assembly, Kitting & Value-Added Services Operations We Design Include:
- Light manufacturing and sub-assembly operations
- Mixed-model and batch assembly lines
- Work-cell and line-based production layouts
Postponement and late-stage customization operations - Pick-to-kit, build-to-kit, and ship-to-kit processes
- Labeling, packaging, and re-pack operations
- Product configuration and customization services
- Quality inspection, testing, and rework areas
- Ergonomic manual workstations and tooling
- Semi-automated assembly and kitting solutions
OPSdesign delivers manufacturing and VAS operations that improve productivity, reduce complexity, and provide the flexibility needed to adapt to evolving business and customer requirements.
