Lean Facility Design : Typical Steps
What Is Lean Facility Design?
Application of LEAN learning & concepts on organizations’ future projects, so that MUDA (waste) can be PREVENTED at the design/ ‘early’ stage!
This is applied as a ‘Preventive Measure’
Why Lean Facility Design?
- Material FLOW improvements
- LEAN process design – even processes of service delivery
- Ergonomic workplaces
- Customized, count-free storage containers
- Inventory Management, Storage as per the frequency of issue
- Lean warehouse for optimization of flow
- Investment in ‘right-size’, multiple, easily maintained, flexible storage equipment
- LEAN/Cellular layouts
- Warehouse Space Optimization
- Multi-skilled, multi-tasking manpower
- Design for material storage (using FIFO racks, wherever possible)
- Design of Supermarkets for storage of spare parts
- Lean internal logistics systems (supporting JIT operations internally)
- Visual management information/data
Typical impacts of the 14 step process of Lean facility or layout design are as mentioned below:
- Reduced floor space/storage space requirement
- Creation of FLOW & PULL in order to reduce inventory and manpower allocation
- Reduced capital investments (in certain areas), all of which will offer better productivity, reduced throughput time, lower waste etc.
- Lean Facility Layout design: better material & information flow
- Right sized logistics equipment planning
Case studies are available on request. Feel free to write to us for more details.
|1||Throughput Time||17 Days||8 Days||52%|
|2||Inventory – Value Steam 1||4200 Mn||1630 Mn||61%|
|3||Inventory – Value Steam 2||1460 Mn||980 Mn||33%|
|4||No. of Operators||240||200||–|
|6||Free Space||750 Sq.m||1550 Sq.m||800 Sq.ft|
|7||Distance Travelled||255 m||85 m||66%|