Lean Facility Design© – Secret to World-Class Layout Design

May 29, 2021by Faber Infinite

Lean Facility Design© (LFD) is a unique framework designed and developed by Team Faber Infinite Consulting which supports an organization to build World class layout Design from day zero. LFD ensures that the new plant layout becomes efficient and effective right from day zero.

This framework is applicable across industries and sectors for organizations that want to set up a new greenfield project. And design a new layout, as well as for those that want to take up a brownfield project or expand their current facility. This framework helps develop flexible, effective, and efficient facilities.

Lean Facility Design© (LFD) is a 14-step approach and that typically covers:

1. Streamlining the manufacturing flow from raw material receipt to finished goods delivery, Optimizing warehouse space

2. Manpower planning

3. Inventory design for raw material, WIP, and finished goods

4. Analysis of capacity and plans for ramping up

5. Material handling and storage design using FIFO,

6. Most importantly, creating an efficient and comprehensive layouts and much more.

It typically has an impact on reducing floor space, delivering best-in-class flow design, lowering capital investment in specific areas of operation, reducing throughput time, best-in-class layout, improving manpower productivity, and planning logistics equipment correctly sized.

Lean Facility Design Framework

We are pleased to share the transformation journey of a client in the packaged food industry, which has implemented the Lean Facility Design Framework.

Team Faber Infinite is assisting the client in the ready-to-cook food and spice industry with 5 to 6 units in their new greenfield plant and build a world-class layout considering all the food and health standards and even the latest Industrial Internet of Things (IIoT) concepts. This master layout is set to be built on 18 acres of land with a project cost of approximately INR 100 crores, employing over 600 people.

Pickles, papad, fruits and vegetable processing, millet processing, health foods, and nutraceutical, ketchup and curry pastes, frozen foods, Indo Chinese mixes, Indian traditional cuppa foods, blended spices, spice mixes, single ingredient spice, instant mixes, IQF, and many more SKUs are amongst the FMCG items which shall be produced by the company.

Our consultants along with client teams have mapped all processes in detail, and including future states for each process have been mapped to define how it can be improved. Five value streams have been identified through PPQ (Product Process Quantity) analysis. For equipment selection, our consultants mapped all existing equipment and based on future capacity calculations – determined requirements of new machines & specifications, while also discussing what changes must be made to the existing machines to accommodate entirely new technologies.

Team Faber Infinite’s consultants have been delivering excellent results in the FMCG industry via the proven and customized LFD framework thus delivering significant benefits to the organization.

Take a step to transform your organization through Lean Facility Design© by Faber Infinite. Contact us today at [email protected].

Written by Faber Nency and Compiled by Faber Mayuri

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    Faber Infinite is an International Business Management Consulting Organization offering consulting solutions and services for Increase Profitability in Business.

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