Minish Umrani, Founder of OptiSpace, in a factory

Every Factory Has a Next Step. Let's Step Up Together.

Smarter Layouts. Better Flow. Process-First Planning.

OptiSpace — factory floor plan overlaid on a live production line

We Build Your Factory — Just Like Your Machines.

Every part placed with purpose. Built for output. Built for what's next.

OptiSpace — factory building with future expansion area highlighted

Plan Right. Build Once. Perform Forever.

We think INSIDE the box.

Process first. The building takes shape around it.

250+

Businesses Transformed

20+

Years of Expertise

75+

Industrial Segments

Industries

We Have Served

Automotive
Electronics
Construction
Chemical
Packaging
Commercial Kitchen
FMCG & Food
Furniture
Steel & Heavy Metals
Logistics
Plastics & Polymers
Pump, Valve, Tube

...and 60+ more industrial segments across Maharashtra, Gujarat, Karnataka, Rajasthan & beyond.

The Philosophy

We think INSIDE the box.

Process first. The building takes shape around it.

Trusted By

Our Clients

A snapshot of the manufacturers and enterprises we have partnered with across more than 75 industrial sectors.

InstaSine
Emerson
Derby
Vidya
Top Gear
Suttatti
Indeal
GUKSS
Gelolife
Paleka
NPB
Metplast
InstaSine
Emerson
Derby
Vidya
Top Gear
Suttatti
Indeal
GUKSS
Gelolife
Paleka
NPB
Metplast
NHP
Masstech
Lift
Burckhardt
ACPL
Accurate
L&T
Kaman
Kineco
Katdare
Kalika
NHP
Masstech
Lift
Burckhardt
ACPL
Accurate
L&T
Kaman
Kineco
Katdare
Kalika
Awareness

What Will LFB Do to Your Factory?

Most factories are designed around the building first, and the process is forced to fit inside it. The result is extra movement, waiting, and inventory you pay for every day. LFB changes how your factory works, starting from the design stage .

01

Your Building Stops Fighting Your Process

Today: the process is squeezed into a fixed building. With LFB: the building is shaped around your product flow.

02

Hidden Waste Disappears

Today: transportation, motion, waiting, and excess inventory are treated as normal. With LFB: they are designed out before construction begins.

03

Change Stops Being Expensive

Today: new volume, products, or automation mean costly rebuilds. With LFB: the facility adapts and expands without starting over.

04

Running Costs Stop Quietly Growing

Today: energy, handling, congestion, and rework keep draining money for years. With LFB: early lean decisions cut these costs across the lifecycle.

What Changes After LFB

Material travels less, and handling drops

Production flows smoothly without stop-start bottlenecks

Less WIP inventory and shorter lead times

Better productivity, quality, and safety for your people

A factory ready to grow when your business does

20-30%

Typical reduction in material handling costs

See what LFB can change
Success Stories

Real Factories. Real Impact, in Numbers.

When the process drives the building, the results show up on the shop floor and in the balance sheet. Here is what our clients achieved with Lean Factory Building.

Automotive Components 01

New plant designed around the flow

Layout was finalised before the building, removing back-and-forth movement between shops.

30%

Less material handling

40%

Shorter lead time

Consumer Goods 02

Expansion without rebuilding

A flexible column grid let the client add capacity without disturbing running production.

2x

Capacity in same footprint

35%

Lower WIP inventory

Engineering 03

Safer, cleaner, lower running cost

Separated pedestrian and forklift paths, with utilities placed close to point of use.

25%

Lower energy use

50%

Fewer floor incidents

50+

Projects delivered

5M+ sq ft

Factory area planned

20-30%

Typical material handling savings

30%

Average lead-time reduction

Our Approach

How we are different

Unlike conventional factory designers, we start with shop-floor operations and systematically eliminate Lean "Mudas" before any architectural design begins.

Minimal Transportation

Near-zero movement between processes

Optimized Motion

Workstations designed for efficiency

Lowest WIP

Balanced process flow, minimal inventory

No Waiting

Material waiting time reduced to minimum

By creating seamless and balanced shop-floor operations, we deliver measurable business impact — higher productivity, reduced inventory levels, improved quality, and lower overall manufacturing costs. Once the production system is optimized, we translate these lean workflows into a purpose-built factory architecture: a building designed to support and enhance operations, rather than restrict them.

Let's Talk

Have a factory in mind?

Whether it's a new facility or an existing one that needs a rethink, let's talk about how Lean Factory Building can work for you.

Portfolio

Featured projects

View all projects
Minish Umrani — Founder & CEO
About The Founder

Mr Minish Umrani

Founder & CEO

Lean Black Belt — USA Inventor

A Lean Black Belt-certified expert with two decades of hands-on experience driving manufacturing excellence across industries. From factory floors to boardrooms, Minish has led over 250 transformations — building leaner, faster, and more profitable operations for businesses across the globe.

20+

Years in Manufacturing Excellence

250+

Factory Transformations

Credentials & Recognition

Lean Black Belt (Crane University, USA)
Six Sigma Black Belt
Registered Expert, NPC, Govt. of India
Member, MCCIA, Pune
Udyog Mitra Award Recipient
Our Process

From First Call to a Factory That Flows

A clear, step-by-step path where the process leads and the building follows. You know what happens at every stage, and what you get from it.

  1. STEP 01

    Discover

    We study your products, volumes, and current flow.

  2. STEP 02

    Design the Flow

    We balance processes and plan the ideal shop-floor layout.

  3. STEP 03

    Shape the Building

    Column grid, spans, and utilities are set to support the flow.

  4. STEP 04

    Build & Commission

    We support execution so the plan is built as designed.

  5. STEP 05

    Improve Continuously

    Post-commissioning reviews keep the factory improving.

Ready to start with Step 01?

A short call is all it takes to map your factory's first steps.

Frequently Asked Questions

Everything You Need to Know

Answers to the questions we hear most often — from factory owners, plant heads, and project teams across India.

About Lean Factory Building (LFB)

Lean Factory Building (LFB) Architecture© is a methodology where the production process is designed first, and the factory building is designed around it — not the other way around. Instead of fitting machines and workflow into a pre-decided building shape, OptiSpace starts by optimizing product flow, cycle times, and material movement, then designs the column grid, structure, and utilities to support that flow efficiently. LFB was developed by Minish Umrani and is the first methodology of its kind in India.
OptiSpace designs and builds factories the way they actually work — instead of drawing a building first and fitting your production line into it, planning starts from your process (how material moves, how products flow, where machines and people work), and the building is designed around that flow. This covers everything from lean layout design to full architectural, structural, and MEP drawings, statutory approvals, and construction support — all under one roof.
A regular architect typically designs the building shell first — plot layout, elevation, structure — and the client's production process is then forced to fit inside it. LFB reverses this: process and material flow are studied and optimized first (cycle times, bottlenecks, manpower, movement paths), and only then is the building — grids, spans, height, utilities — designed around that flow. This avoids the common problem of a factory that looks good on paper but has long walking distances, awkward material handling, and costly modifications after construction.
Typical outcomes include a 20–30% reduction in material handling costs, along with smoother continuous production flow, lower work-in-process (WIP) inventory, reduced operator movement, fewer bottlenecks, and lower operating costs across the facility's lifecycle. Because waste is eliminated at the drawing-board stage rather than fixed after construction, rework risk is also significantly lower.

Services: Greenfield, Brownfield & Post-Commissioning

A Greenfield project is the design of a factory on a new or vacant plot, starting from a blank canvas. OptiSpace studies your product families, volumes, and value streams first, develops the ideal lean layout, and then designs the architecture, structure, and MEP (electrical, plumbing, HVAC, fire protection) around that layout — including statutory approvals, 3D visualization, and construction supervision.
A Brownfield project is the improvement of an existing, already-running factory — re-planning the internal layout and material flow to remove waste without necessarily changing the building shell. This suits companies dealing with delayed deliveries, congestion, high WIP, poor space utilization, or difficulty scaling within their current facility.
OptiSpace offers both. Clients can take just the Lean (GEMBA) layout and execute it independently, or opt for the full turnkey path — architectural, structural, and MEP drawings, statutory approvals, 3D visualization, and construction supervision — all delivered by one team under one roof.

Process & Getting Started

Most engagements begin with a complimentary Pulse Check Visit, where the team visits your facility to observe operations, understand your process, and discuss pain points (only travel charges apply). This is followed by a techno-commercial proposal outlining scope and fees, and once approved, the detailed lean diagnosis and layout work begins.
Yes. Every engagement starts with a complimentary Pulse Check Visit, where the team visits your facility in person to observe operations, understand your process, and discuss your specific challenges before any proposal is made (only travel charges apply). Site visits continue through the project for data collection and, where opted for, execution supervision.
To prepare a lean layout, OptiSpace typically needs your product and process details (part list, product families, process sequence), production volumes and demand forecast, a machine list with dimensions and specifications, your current factory layout (if any) or plot dimensions and site survey, manpower and shift details, and any statutory or safety requirements specific to your industry. Much of this is gathered directly during the Pulse Check Visit, so clients don't need to have everything ready in advance.
Deliverables typically include a proposed Lean (GEMBA) layout in CAD/PDF, and — for full-scope projects — a complete construction drawing set (architectural, structural, MEP), 3D images and walkthrough video, and support through statutory and regulatory approvals. OptiSpace also offers lifetime video-call consulting after project closure.
Yes. OptiSpace doesn't stop at handing over drawings — the team offers execution assistance to help translate the lean layout from paper to the factory floor with precision, along with lifetime video-call consulting for questions that come up even after project closure.
Project cost depends on scope — whether it's a lean layout-only engagement or a full turnkey Greenfield build with architecture, structural, MEP work, and construction — as well as plot size and project complexity. There is no fixed rate card; after the complimentary Pulse Check Visit, OptiSpace shares a detailed techno-commercial proposal with fees clearly outlined for the specific requirement.

Credentials, Experience & Compliance

OptiSpace is a division of Solutions Kaizen Management Systems, founded by Minish Umrani, who holds a Lean Black Belt from Crane University, USA, and a Six Sigma Black Belt. He is a Registered Expert with the National Productivity Council (NPC), Govt. of India, a member of the Mahratta Chamber of Commerce, Industry & Agriculture (MCCIA), Pune, and has led 250+ factory transformations over 20+ years.
Over 20 years, OptiSpace's parent company Solutions Kaizen Management Systems has completed 250+ factory transformation projects across 75+ industrial segments, including Automotive, Electronics, Chemical, FMCG & Food, Steel & Heavy Metals, Packaging, Logistics, Furniture, and Plastics & Polymers, across Maharashtra, Gujarat, Karnataka, Rajasthan and beyond. Clients include L&T, Emerson, Burckhardt Compression, and Reliance.
Yes. For Greenfield projects, OptiSpace manages municipal building permissions, industrial area approvals, environmental clearances, Fire NOC documentation, and occupancy certificates, alongside ensuring Factory Act compliance — safety and welfare provisions, sanitation standards, worker amenities, and emergency egress planning.
Contact the team via WhatsApp, phone (+91 76662 58956), or the website's contact form to schedule a complimentary Pulse Check Visit, where OptiSpace visits your facility to understand your requirements, project scope, and pain areas before proposing a scope of work.