From Complex Chaos to Coordinated Control
How a Manufacturing Company Relocated Operations Without Missing a Beat
The Situation Before
A legacy manufacturer operating out of Lenexa, Kansas, was preparing for a high-stakes transition: relocating its full-scale manufacturing and warehouse operations to a 150,000-square-foot facility in Olathe. The company was working under new ownership, juggling aging infrastructure, growing demand, and a pressing need for more efficient space.
The stakes were high. The move had to be precise. Any disruption could impact customer commitments and manufacturing continuity.
The Obstacle
Despite recognizing the need for project support, the company wasn’t entirely sure what to expect from external project management. With internal leaders focused on day-to-day operations, they lacked the time and expertise to plan and facilitate a move of this scale. As the complexity mounted—especially with the move involving two separate facilities and a follow-on material handling redesign—it became clear they needed a different skill set.
The Turning Point
That’s when SRS stepped in.
I began with a discovery phase and quickly expanded the scope to include detailed planning, daily progress meetings, and phased execution. We didn’t just move machines—we applied our relocation playbook.
We developed a machine grouping matrix to prioritize and sequence the move, introduced twice-daily communications meetings to keep teams aligned, and created dashboards and timelines that brought visibility and control to a complex and fast-moving process.
The internal team began to refer to the relocation planning as “the playbook”—a sign of how the structured approach was embraced. One executive described Tom as a “trusted advisor,” and the VP of Supply Chain requested continued support into the post-move stabilization phase.
Tangible Wins
Zero production downtime during machine relocations
All machines operational at the new site by the end of February—right on plan
Built and executed a phased move strategy that integrated manufacturing, warehousing, racking, and material flow
Introduced visual dashboards and issue tracking for daily updates across both buildings
Supported the development of a material handling transformation plan, including flowcharts, standards, and staffing recommendations
Project completed on schedule, despite winter storms and tight space constraints
Ripple Effects
Beyond the physical move, the company gained:
A reusable relocation playbook for future transitions
Stronger cross-department collaboration through daily command center meetings
A renewed commitment to systems transformation (including an upcoming ERP implementation)
Confidence to tackle lingering material handling inefficiencies
Final Thoughts
Relocating a live manufacturing operation is no small feat. But with the right planning, sequencing, and communication tools in place, even the most complex transitions can feel manageable.
“Tom provided the structure, insights, and execution we needed. Top leadership said it best: ‘I’ve never experienced a move that went as smoothly as this one... in the end, the move became a non-event.”
Thinking about a facility relocation, expansion, or major reorganization?
Let’s talk.
At SRS, we simplify the complex—so you can keep your business running while we handle the heavy lifting.