In our microalgae plant, we faced energy loss and equipment wear early on—turned out the issue wasn’t faulty tech, but our layout. Mechanical lines crisscrossed with electrical and piping, causing flow delays, heat loss, and tough maintenance. We mapped real workflows, involved the team, and redesigned with logic—shorter pipe runs, proper insulation, and zoned utilities. Once we fixed the layout, energy use dropped, uptime rose, and our microalgae output became far more consistent and efficient.

a plant layout isn’t just about space—it’s about flow, visibility, and ownership. When workflow efficiency falls short, it’s often rooted in how teams move, communicate, and access resources. I’ve found real improvements come when the people closest to the work are involved. I walk the shop floor, ask questions, and encourage operators to share layout pain points and ideas. Cross-functional brainstorming with production, maintenance, and logistics helps unlock practical changes—sometimes simple, like relocating tools or adjusting material flow paths. When teams feel heard and part of the solution, implementation becomes smoother and the results more sustainable. Empowering the team creates a layout that works with them, not against them

Seek their input, observe with them, involve in planning , pilot changes with feedback, and establish continuous improvement.

Involving the team starts with holding brainstorming sessions to gather their insights on pain points and possible improvements. I’ve found that encouraging walk-throughs of the current layout helps uncover inefficiencies that might be missed on paper. Team members often have first-hand experience with daily operations, so I rely on their input to propose and test small, incremental changes. Creating this collaborative environment not only improves the workflow but also makes the team feel valued and engaged in the process.

Toolbox Talks is a great tool to engage a team with KPI's, Lean Waste, 5s, that will help to achieve the desired results and team empowerment. I find TT to be a great tool that encourages individuals and the team to discuss elements when something goes wrong and to plan a collective solution. Brilliant CI tool!