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Home > About Us > Upcoming Events > Public Workshops > Plant Layout for Lean Manufacturing


You will learn the tested methods used by experts on how to rearrange and optimize your existing plant layout or consolidation. Learn the proper analysis of workflow, space and other important relationships to lower costs and improve profits. You will learn through hands-on, step-by-step exercises, how to reduce materials handling, develop layouts and integrate new technologies. This workshop is designed for companies who are looking to:

• Rearrange the layout of the plant
• Optimizing space for performance or increased capacity
• Expand plant facilities
• Consolidate plants
• Relocate the plant


Workshop Overview

Step by Step
◊ Plant layout methods
◊ 7 major waste streams
◊ 13 step patter of procedures
◊ The 3 "A's" of plant layout

Data Gathering
◊ Data collection needs
◊ Product/quantity contribution analysis
◊ Push vs. pull comparison
◊ Small batch vs. large batch production and single piece flow
◊ Flow to suit access and egress patterns
◊ Operation process charts

Importance of Setup Reduction

Material Flow Analysis
◊ Overlap of macro and micro analysis
◊ Developing macro operation process charts
◊ Multi-product considerations

Developing Process Matrix and From-To Charts

Analyzing Material Flows
◊ 3 Metrics to use
◊ Applying to the From-To charts
◊ Ranking methods for discrete/unit material flow

Important Non-Flow Considerations

Combining Flow and Non-Flow Considerations
◊ Avoiding "weighting" pitfalls
◊ An effective simple tool for combining flow and non-flow relationships

Establishing Closeness
◊ Pitfalls to avoid with the classic approach

Hands-On Problems
◊ Team Assembly/Batch Sizing
◊ Develop relationship diagram based solely on non-flow considerations
◊ Develop combined flow and non-flow based relationship diagram and factory block layout

Flexibility Considerations

Distance Intensity Charts

Importance of Spatial Relationship Diagrams
◊ Major aisle considerations

Multi-floor Multi-Building Example
◊ Allocating space assignments

Team Plant Layout Problem
◊ Develop streamlined factory block layout with major aisle considerations

Determining Space Needs
◊ Ways to capture/estimate space
◊ Example conversion method

Storage Area/Warehouse Layout Planning
◊ ABC Analysis
◊ Space requirements
◊ Equipment alternatives

Comparing Alternatives
◊ Evaluating tangible and intangible criteria

Computerized Approaches
◊ Software demonstration for developing layouts that minimize materials handling costs