Harmonic, Inc. Amplifier Manufacturing

Facility Design | Lean Conversion | San Jose, CA




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Lean Manufacturing, Facility Design

San Jose, CA

Project Type

Project Size
30,000 sf

Project Duration
12 months

Harmonic is leading the transformation for video, cable and media companies, with smarter, faster, and simpler solutions. Increased demand resulted in order high backlogs and longer production cycle-times that DCI addressed with Demand-pull production technologies.

  • Modular manufacturing facility design maximized flexibility for future changes
  • Production rate and capacity analysis-driven design
  • Point-of-use inventory storage with auto-replenishment
  • Dock-to-stock supplier awards to improve efficiency.
  • 30% reduction in material costs with improved strategic procurement methods.
  • Design met the needs of the 5-year forecast.
  • 2x increase in capacity and inventory turns.


  • Facility Design
  • Construction Oversight
  • Supply Chain Strategy

Vendor Coordination

  • Architects
  • Construction Trades
  • ESD Facilitation
  • Raw Material Suppliers