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Lean Facility Design© in India | Layout Design Consultant

  • By hvinfo
  • November 20, 2023

In the dynamic world of business and industry, the pursuit of efficiency is a never-ending journey. Organizations are constantly seeking innovative ways to optimize their processes, reduce waste, and enhance productivity. One powerful solution that has emerged to address these challenges is Lean Facility Design© (LFD), a groundbreaking framework developed by Faber Infinite Consulting. In this blog, we will explore the transformative impact of Lean Facility Design© on various industries and how it is revolutionizing manufacturing efficiency. 


Electrical & Lighting Products: A Brighter Future with LFD 

One of the leading manufacturers of consumer electrical products embarked on a journey of improvement with Lean Facility Design©. The results were nothing short of remarkable.  

  • Their production capacity witnessed a substantial improvement of 12%, enabling them to meet growing market demands.  
  • Moreover, the Value-Added Ratio (VAR) saw a significant increase of 45%, indicating a more efficient and value-driven production process.  
  • Inventory value was reduced by a commendable 20%, demonstrating better control over resources.  
  • The Transportation Index experienced a 30% reduction, reflecting streamlined logistics and reduced costs.  
  • Additionally, Work in Progress (WIP) optimization led to a notable reduction in processing time from 5 hours to 3.5 hours, making the entire production process more efficient. 


Cryogenic Tanks: Fueling Progress with Efficiency 

India’s largest manufacturer of cryogenic tanks found an ally in Lean Facility Design©.  

  • The productivity improvement was substantial, with an increase in production equivalent tanks by 40%.  
  • Manpower efficiency received a boost, with a 42% increase in productivity.  
  • Throughput time saw a remarkable reduction of 37%, allowing for faster production.  
  • The distance traveled by materials decreased by 32%, optimizing logistics and saving time and costs.  
  • This transformation led to impressive financial savings of INR 32 million, making the adoption of LFD a financially wise decision. 


Integrated Food Park: A Flavorful Transformation  

India’s leading Indian manufacturer of a wide range of culinary delights, including spice mixes, pickles, chutneys, thechas, ready-to-eat foods, honey, and more, embarked on a journey of transformation. The Faber Infinite team conducted a comprehensive assessment, revealing disparities in process efficiency between different units within the plant. To achieve consistency and reduce variations, it was evident that standardized work processes and best practices needed to be implemented. 

The results were astounding, with percentage improvements in productivity across various units as follows: 

  • Unit 1: Improved by 41% 
  • Unit 2: Improved by 35% 
  • Unit 3: Improved by 33% 
  • Unit 4: Improved by a remarkable 45% 
  • Unit 5: Improved by 27% 
  • Unit 6: Witnessed an incredible improvement of 50% 
  • Unit 7: Improved by 27% 
  • Unit 8: Improved by 48% 


These remarkable improvements underscore the power of Lean Facility Design© (LFD) in harmonizing operations and enhancing efficiency across diverse units within the Integrated Food Park, ensuring a consistent and optimized production process. 


Solar Panels: Harnessing the Power of Efficiency 

A leading solar panel manufacturer in India harnessed the potential of Lean Facility Design© to achieve substantial cost savings. Through LFD, they saved approximately INR 12 crore in capital investment and freed up INR 45 crore (450 Million)  in operating costs. These significant cost savings not only improved their financial bottom line but also positioned them for long-term sustainability and growth. 


Ceramic Crockery: Crafting Efficiency with LFD 

The ceramic crockery industry witnessed a remarkable transformation through Lean Facility Design©.  

  • Productivity improvements of 47% showcased a workforce operating at its full potential.  
  • Production capacity improved by 25%, allowing the company to meet increased demand.  
  • Throughput time was substantially reduced by 85 days, leading to faster product delivery.  
  • Moreover, the distance traveled by materials decreased by 54%, streamlining logistics and reducing costs.  
  • These enhancements resulted in substantial financial savings of INR 47 million. 

In conclusion, Lean Facility Design© is more than just a framework; it’s a catalyst for change and transformation.
These success stories from diverse industries demonstrate the incredible potential of LFD to optimize manufacturing operations, reduce waste, and enhance productivity.

Whether you are in the electrical and lighting industry, cryogenic tank manufacturing, food production, solar panels, or ceramic crockery manufacturing, Lean Facility Design© has the power to revolutionize your operations and drive efficiency. It’s a testament to how organizations can harness the power of efficiency and innovation to unlock a brighter, more prosperous future. Lean Facility Design© is not just a methodology; it’s a pathway to manufacturing excellence