Optimize your facility and maximize your performance with design and automation solutions
PLG Consulting empowers industrial leaders with comprehensive facility optimization solutions backed by industry-leading design and automation expertise. Our team of over 60 real-world industry veterans brings innovative approaches to transform your physical spaces and workflows with proven solutions that optimize layout efficiency, implement advanced automation systems, and drive value to improve throughput, performance, and utilization. Additionally, our experts bring best practices in the analysis, negotiation, engineering, and start-up of new manufacturing locations and distribution hubs.
Industries We Serve
Our facility design/redesign and automation services extend across multiple industries, including:
- After Market Parts (Access Control/Building Security, Electrical Distribution, Electronics, Heating & Plumbing, Safety Products, etc.)
- Automotive
- Industrial Distribution
- Manufacturing
- Transportation and Logistics
Our facility design and redesign process begins with identifying your current state and understanding your organization’s short-term and long-term business goals. We collaborate with your stakeholders transparently to ensure we recommend and map the best solution moving forward.
Whether optimizing a new facility upfront or redesigning an existing one, our network optimization capabilities and access to the latest technology tools allow us to provide multiple scenarios for design, digitization and automation decisions.
Layout design and optimization
Unlock your supply chain potential via intelligent facility design, optimizing space and workflows to maximize ROI. Our approach includes:
- Future state design requirements
- Lean process design
- Block analysis and facility design layout
- Automation analysis
- Asset management and utilization
- Continuous improvement culture
Automation analysis and solutions
Transform operations through strategic automation analysis, identifying targeted solutions that balance technology investment with performance gains. We offer:
- Financial analysis
- Qualitative considerations
- Current market conditions assessment
- Sensitivity analysis
- Solution recommendations
- Implementation
Smart facility and digitization
Enhance facility performance through smart technology integration and digitization, creating intelligent spaces that optimize automated systems.
- Utility optimization
- Asset management and utilization
- AI for hazard identification
- Environmental analytics and optimization
- Access monitoring
Program management and execution
Drive project success through expert program management, ensuring on-time, on-budget completion.
- Standardized project flow with deliverables
- Phased approach to execution with block layouts
- Reporting and escalation process
- Ramp up and sustainability plan
Utilization and asset management
Maximize facility performance through strategic asset deployment and space utilization. Our experts help you optimize every square foot of your facility while ensuring maximum utilization of all resources.
- Identification of assets such as MHE and equipment
- Reporting and optimization
- Potential for global contracts to minimize costs
Productivity capture & continuous improvement
Drive operational excellence through data-driven performance analysis and continuous improvement strategies. We implement:
- Tracking mechanisms for productivity projects
- Productivity requirements and approval processes
- Cadence and reporting
- Daily management systems
Comprehensive Automation Solutions
Our automation expertise spans multiple technologies and systems:
- Unit load ASRS with 5x labor efficiency and 2x floor density
- GTP | Totes-to-Person and Shelves-to-Person systems
- Autonomous forklifts and AGVs
- Automated truck load/unload systems
- Ergonomic palletizing/wrapping
- Picking/sorting technology
- Autonomous mobile robots (AMRs)
Contact our experts today to reimagine your facility and discover how PLG's design and automation solutions can revolutionize business performance.
Project Examples
Global Manufacturer Realizes $80M in Productivity Gains Through Process Improvement
An over $20B global company that does light manufacturing and value-added processes struggled to meet the cost as a percentage of sales. Many of the processes were suboptimized and treated as if they were unique. The...
Medical Device Manufacturer Achieves US-Based Production at Near-China Costs
A ~$10B global business unit for a Fortune 500 company producing and selling productivity and protective equipment struggled to implement a cost-viable assembly line in the United States (per Customer request) for the medical industry. The...
Industrial Distributor Cuts Energy Costs by 75% Through Facility Digitization
A $20B+ global business that does light manufacturing and distribution needed to identify a way to reduce costs through digitization of multiple sites. One opportunity is in the utility space, specifically lighting and lighting control. Services Provided Working...
Global Fortune 200 Firm Reduces Labor by 78% Through Warehouse Automation
A $20B+ global Fortune 200 company needed to exit a complex warehouse and consolidate it with two other facilities to reduce overhead costs with a centralized operation. The task included relocating outdated carousels for the small...
Distribution Company Achieves 50% Annual Savings Through Supply Chain Optimization
A ~$22B global business providing wire spools cut to size for multiple industries saw a spike in demand in a region. Demand exceeded capacity, creating inventory space issues and cost constraints. Services Provided Working collaboratively with the client,...
Fortune 200 Manufacturer Achieves 400% Efficiency Gain Through Automation Consulting
A ~$10B global business unit for a Fortune 200 company producing and selling productivity and protective equipment was unable to meet demand (backlog up 750%, mostly in North America) during COVID-19. The processes for manufacturing masks...
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