International · Steel Manufacturing · Ontario, Canada
300,000 Sq Ft Expansion - CAD $3.2M in Workforce Costs Eliminated Through Operational Growth Planning
The Situation: A Canadian steel manufacturer undertook a major facility expansion - scaling from 180,000 sq ft to 300,000 sq ft. The expansion projected a workforce increase of 100 additional personnel above their existing 150-person team. Without intervention, the growth would have added ₹20Cr+ in annual labor costs.
What We Did: As Lead Engineers and Project Partners, we designed the full operation with growth efficiency as the primary constraint. Machine sequencing was mapped against production flow, warehouse zoning was structured to minimize operational friction, and the entire system was built to scale without proportional headcount growth.
Plant Size Scaled: 180,000 → 300,000 sq ft
Workforce Growth Needed: 50 people (vs. 100 projected)
Annual Cost Saved: CAD $3.2M against expansion estimate
- Delivered within 3-month project timeline with zero rework
- 22% reduction in material travel distance vs. initial layout
- 25% faster workforce onboarding through process documentation
Engagement Type: Full Growth Operations - Layout · Process Design · Documentation