How can you improve production facility layout to reduce waste?

1 Identify your value streams

The first step to improve your production facility layout is to identify your value streams, which are the sequences of activities that create value for your customers. You can use a value stream mapping tool to visualize the flow of materials, information, and people across your processes, and to identify the sources of waste, such as waiting, overproduction, defects, or transportation. By mapping your current state and your desired future state, you can identify the gaps and opportunities for improvement in your layout.

2 Apply the 5S method

The 5S method is a lean tool that helps you organize your workplace and eliminate waste by following five steps: sort, set in order, shine, standardize, and sustain. By applying the 5S method to your production facility layout, you can reduce clutter, ensure that everything has a place and a purpose, maintain cleanliness and order, establish rules and procedures, and monitor and audit your performance. A well-organized and clean facility can improve your productivity, quality, safety, and morale.

3 Implement cellular manufacturing

Cellular manufacturing is a lean concept that involves grouping machines and equipment according to the products or families of products that they process, rather than by their functions or types. By implementing cellular manufacturing in your production facility layout, you can reduce the distance and time required to move materials and products between different processes, minimize inventory and work in progress, enhance flexibility and responsiveness, and improve communication and teamwork.

4 Optimize your layout type

Depending on the nature and volume of your products and processes, you can choose from different types of layouts for your production facility, such as product layout, process layout, fixed position layout, or hybrid layout. Each type has its own advantages and disadvantages, and you should optimize your layout type according to your specific needs and goals. For example, a product layout is suitable for high-volume and standardized products, as it allows a smooth and continuous flow of materials and products along a line of machines or stations. A process layout is suitable for low-volume and customized products, as it allows flexibility and variety in the arrangement of machines or stations according to their functions or types.

5 Use simulation and testing

Before implementing any changes to your production facility layout, you should use simulation and testing tools to evaluate the impact and feasibility of your proposed solutions. You can use software or physical models to simulate the flow of materials, information, and people in your new layout, and to identify any potential problems or bottlenecks. You can also test your new layout in a small scale or in a pilot area, and collect feedback from your workers and customers. By using simulation and testing, you can ensure that your new layout meets your expectations and requirements, and that it can be implemented smoothly and effectively.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?