How IGT Consolidated 17 Facilities into One High-Performance Manufacturing Operation

The Client: International Game Technology (IGT)

International Game Technology (IGT) is a global gaming technology company serving regulated markets across gaming machines, lottery, digital channels, and sports betting. With complex product configurations and evolving customer requirements, IGT needed a manufacturing model that could support both scale and customization.

To modernize operations in Reno, IGT partnered with FloStor to redesign facility flow, improve production responsiveness, and reduce operating friction.

The Challenge

• Fragmented Facility Footprint: Manufacturing and warehouse operations were spread across 17 separate sites, creating coordination delays and unnecessary transport movement.
• Customization Complexity: Smaller order sizes and higher product variation increased planning and changeover pressure.
• Late-Stage Order Volatility: Customer changes late in the production cycle disrupted schedule stability and workflow continuity.
• Job-Shop Limitations: Legacy process design constrained throughput and made lead-time reduction difficult.
• Cost and Inventory Exposure: Existing material flow and staging practices tied up working capital and reduced operational agility.

The Solution

FloStor designed and implemented a consolidated manufacturing strategy centered on process integration, controlled product flow, and scalable assembly operations. IGT transitioned from 17 distributed facilities into a single 260,000-square-foot operation in Reno, creating one coordinated production ecosystem.

The new operating model combined powered movement, pull-based replenishment, and workstation ergonomics to improve flow reliability while preserving the flexibility required for high product variation.

Systems Used

• Facility Consolidation Program: Seventeen-site footprint consolidated into one integrated manufacturing and warehouse center.
• Powered Roller Conveyor Network: Progressive assembly flow replaced non-powered movement and reduced manual transfer points.
• Flexible Multi-Line Assembly Cells: Eight lines with ergonomic workstations enabled mixed-model slot machine production with rapid changeovers.
• Kanban and Barcode-Driven Kitting: Common parts were replenished just-in-time and custom parts were staged in barcoded kits for accuracy.
• Flow-Control Sensor Logic: Accumulation and release controls maintained spacing discipline and reduced line starvation/blocking.

The Power of Integration in Action

FloStor’s integrator approach aligned material handling, workstation design, replenishment logic, and production controls into one synchronized system. Instead of treating assembly, inventory, and movement as separate functions, the new architecture connected them into a continuous operation.

This integration gave IGT stronger responsiveness to demand shifts while reducing the operational burden associated with fragmented workflows and manual coordination.

The Results

IGT moved from a distributed, high-friction operating model to a centralized and flexible production system that improved throughput control, reduced inventory drag, and supported higher customization with less disruption. The redesigned flow improved speed-to-ship performance while strengthening execution consistency.

By combining consolidation and automation, IGT established a more resilient platform for continued growth and ongoing process improvement.

Why This Worked

The initiative succeeded because IGT and FloStor combined physical redesign with operational discipline, not just equipment upgrades. Consolidation, line engineering, and replenishment logic were implemented as one strategy with measurable business outcomes.

• End-to-End Process Alignment: Layout, flow, and controls were designed to work as one cohesive system.
• Built-In Flexibility: Mixed-model line capability preserved responsiveness in a customization-heavy market.
• Operational Transparency: Better material visibility and controlled release logic improved day-to-day decision quality.
• Scalable Foundation: The consolidated platform positioned IGT for sustainable growth and future optimization.

Related Services

• System Integration and Manufacturing Flow Design
• Conveyor and Assembly Line Engineering
• Warehouse and Inventory Optimization
• Scalable Operations Planning and Lifecycle Support