Affordable Interior Systems

Affordable Interior Systems (AIS)


Leominster, MA



Project Type:

Industrial Engineering

Created a Master Plan for a consolidation of 4 Manufacturing and Storage locations into a single facility, along with implementation of a new WMS system for parts tracking.


  • New consolidated and Lean layout increased manufacturing labor efficiency by 25%.
  • Implemented 3 new Balyo robot fork trucks with ROI under 18 months.
  • Optimized areas to allow for 200% growth in reduced footprint.
  • Implemented WMS to enable improved on-floor and stockroom parts tracking.
  • Improved overall Inventory accuracy from 92% to over 99%.
  • Developed manufacturing process with less reliance on fork-lifts.
AIS Interior

Steve Savage

Chief Operating Officer

"AIS utilized Boston Industrial to review our future state layout and recommend further changes as we consolidated our manufacturing facilities from five buildings down to one. This was a very exciting and successful project, and Bob and his team were very active team members. I highly recommend Boston Industrial, they really know stuff and they offer a very practical approach to process improvements (lean)."

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