Layout Design

Layout Design

Lean plant layout focuses on value streams, all value-added steps from raw materials until the delivery to your customer. Lean layouts are more likely to combine processes horizontally across the factory. Plant Lean layout defines a systematic way to eliminate waste in the entire value stream.

Factory Layout as per lean Concepts

Customer Requirement

To re-layout the shopfloor with legacy systems as per the lean concepts

Current Process

Material flow and process flow is not as per the industrial engineering norms

GEENO’s Proposal

7 step process to re-design the layout

7 Steps Layout Definition

1. Define Problem

2. Brainstorm

3. Define Process Flow

4. Impact Estimation

5. Design

6. Simulation

7. Layout

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Process of Plant Layout Design

Process Mapping
Product / Process Constraint Mapping
Material Information and Flow Analysis
Line balancing study & Takt time / CT analysis (Adopting LEAN guidelines)
PAPER workshop / Layout 2D simulation
CARDBOARD workshop / Layout 3D simulation

Scope can be set precisely as below

1. KANBAN / suitable alternate system implementation

Design WIP stocking methodology
Fixing production batch qty
Fixing WIP stock qty
Stock replenishment time
Safety stock qty
Fixing launcher for product change

2.    Supply of Material storage & handling system identified in layout design
3.    Inbound / Outbound logistics definition
4.    WIP / FG / input materials storage system design – Just needed inventory
5.    Sustenance of System & Results

Safety stock management rule
Escalation matrix
Safety stock withdrawal rule