Scale · Full Plant Design & Execution
End-to-End Plant Design and Execution That Actually Runs
Two problems, one method. Whether you can't make enough, or you can make enough but not profitably, the answer starts the same way: find the real constraint with measured data. Then we design and execute the whole system — equipment, layout, utilities, people, and controls — from assessment to full-rate startup.
Engagement at a Glance
- Typical range
- $28K assessment to $1M+ build
- Duration
- 2–3 weeks to assess; 8–14 weeks per execution phase
- Structure
- Assessment first, then phased execution
- Deliverables
- Capacity model, system design, installed and commissioned line
- Method
- Theory of Constraints — station by station
- Ends with
- Your line running at rate without us in the building
An engineer responds within one business day.
What you get
1. Outcomes
The real constraint, named
Most capacity problems aren't where they look. We measure every stage, decompose true OEE, and put money only where the bottleneck actually is.
A line that grows with you
Designed for the phase after this one — so next year's growth is an add-on, not a rebuild.
Cost per unit goes down
The design does the cost-cutting: less labor per case, less waste, fewer touches, tighter changeovers, less overtime. Margin improves because the process did — not because someone was told to work faster.
How it works
2. The Process
Step 1
Assess and model
We walk your operation and build a stage-by-stage capacity model with measured rates, not nameplates. The constraint gets named, with numbers behind it — and often it isn't the machine you were about to buy.
Step 2
Design the system
Equipment, layout, utilities, and controls as one integrated design, with scope, schedule, cost, and acceptance criteria you approve before anything is bought.
Step 3
Execute
Procurement, fabrication in our shop, installation, integration. One team owns all of it — including the utilities and facility work that usually falls between trades.
Step 4
Start up at rate
Commissioning with your operators until the line hits its numbers, then training and documentation so it keeps hitting them.
Proof
3. Recent Work
Recent: a capacity assessment for a refrigerated foods manufacturer found the bottleneck wasn't the filler they were about to buy — it was the chill loop — and true OEE was running near 58% against an assumed 95%. The added capacity they needed was already sitting in their own facility.
Launch Partners at a Glance
- Longest client
- 8 years and counting
- Delivered
- 100+ projects
- Largest program
- 52 identical machines, 4 runs, one OEM
- Team
- 12 people + in-house shop
Related reading: Start with the assessment: capacity planning & bottleneck analysis · New line or retool? A decision framework · Why your capacity model says 95% and your line says 58%
Straight answers
4. Questions We Hear
Do you only design new lines?
No. We also improve existing plants: retooling current machines, adding automation, taking cost out of lines that already run, and building maintenance programs that keep them running.
We can make enough. The margin just isn't there. Can you help?
That's a large part of what we do. We measure where the cost actually goes (labor per case, yield loss, scrap, changeovers, overtime, utilities), then fix the constraint driving it. Sometimes that's automation, sometimes a tooling change, and sometimes a scheduling change that costs nothing.
How long does an assessment take?
Two to three weeks. We walk your operation, build a stage-by-stage capacity model with measured rates, and name the constraint with numbers behind it. Then you decide whether, and how, to execute.
Do you work outside Colorado?
Yes. We're based in Arvada, in the Denver metro, and build nationwide. Recent work spans Texas, Nebraska, Florida, California, and Illinois, plus a federal production contract shipped from our shop.
Start here
5. Talk to an Engineer About Full Plant Design & Execution
Tell us what you're up against. It takes twenty seconds, and the second step is optional.
Prefer to talk? 720.394.9437 · Mon–Fri, 9 AM – 5 PM MT. Ask for Taylor.
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An engineer responds within one business day. Not a salesperson.
Prefer to talk? 720.394.9437 · Mon–Fri, 9 AM – 5 PM MT. Ask for Taylor.
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