What are the best ways to design a lean layout and workcell for maximum efficiency and ergonomics?

I believe the first step is to ask the employee/team for help, there is no point even trying to change layouts, or new ways of doing things without employee buy-in. You need the experts in the process to help define value added for themselves and the customer. Without this, the system will simply fail, due to resistance to change.

In my experience below are the ?????????????????? ????????????????'?? for mapping the value stream of a particular product: 1. ???????????? ???????????????? ???????? ?????????? ???????? ?????? ?????????????? ???????????? that will contribute for highest lead time. 2. ?????? ???????? ?????? ???????????? ?????????????????? ???????????????? ???? ?????????? ????????????????. 3. ???????????? ?? ???????????????????? ?????????????? for visualizing constraints within and among all processes.

Defining the value stream at multi plant level, door to door level or individual process level is important based on current and long term business priorities. While choosing whether to start at a process level or plant level or multi-plant level depend on business requirements and area of influence; sometimes, constraints at all levels can be targeted at a time at criticality level. It all depends on available bandwidth and business value expected out of it.

As per my experience, there are various internal factors that result in deciding which type of agile layout we should opt for. These Internal factors are as follows: 1. ?????????????? ???????? - Weight, Bulkiness, Critical to Quality 2. ?????????????? ???????? - Critical to Safety, Lot Size 3. ?????????? ?????????????? - Ergonomic Assessment ???????? ???????? ??????????

Selecting the right layout for your business for example in case of foam & spring mattress covers stitching and fabric cutting floor is pivotal. Consider functional layouts that group similar processes for flexibility, but be wary of long queues. A cellular layout, forming specific cells for product families, can minimize transport time. For a streamlined production flow, a product layout is ideal, especially for high volume. Alternatively, a hybrid layout, blending various elements, might offer the best balance for your specific needs.

Choosing a product lay out, process lay out or job layout depends on the product and the value stream. Cellular/flexible lay outs often introduces flow and intermediate between process and product lay out. For product layouts creating a single piece flow is very critical. For job lay outs, enabling support mechanism in terms of man-machine-material is crucial. Layouts depend heavily on line balancing & people flow, material feeding mechanisms & easy access to machines.

look for lazy employees! They will look for improvements and shortcuts. They will get you ahead - not those who do things by the book. Work smart - not hard

One thing I have found helpful is using ???????? ???????????????? (Eliminate, Combine, Rearrange, Simplify) for identifying and eliminating/ reducing waste in Gemba. There are 100+ ???????? ?????????? available but most important thing is to decide which tool to use when and in what sequence for achieving the best possible outcome.

Lean principles must applied in 12 possible guiding principles derived from a 3-M X 4-M matrix form. 3-M stands for Muri-Mura-Muda, 4-M stands for man-Machine-Material-Method. This approach is very powerful. Selection of priority will depend on Impact-effort matrix.

Take into account the different physical builds of your employees. Different body sizes must be taken into account when positioning the workpieces and tools (accessibility) as well as the working height! It may be necessary, for example, that the working height is adjustable, etc.

Ergonomics is very important from a employee life cycle point of view. Many times, these issues are not tangible to white collar employees designated for supervising work, but standing 8 hours on a daily basis is a tough job. Bending, lifting, reaching--creates stress of bio-mechanical system (joints, tendons, ligaments, muscles) of human body. Right posture, frequency of repetition & load being handled are all very impactful in ergo analysis. Workstation layouts, handling aides & gender neutrality are key aspects of ergonomics implementation.

There are two important Ergonomic KPIs I learned while working at Denso (Toyota). 1. ?????????? ????????: (Total Line Length/ Distance travelled by Child part to become finished goods at End of line) * 100 2. ???????????? ????????: (No. of operating points within range of 30-50 cm. / Total no. of operating points) * 100 Apart from these 2 parameters, REBA RULA Assessment is important identifying ergonomic issues.

To refine the layout and workcell for your business for example in case of mattress cover stitching and fabric cutting, utilize the PDCA cycle. Begin by setting specific goals like reducing cycle time or improving quality. Measure your outcomes, and use tools like histograms to evaluate performance. If there are issues, brainstorm solutions, maybe through fishbone diagrams, and implement the best ideas. Regularly reassess to ensure continuous improvement.

16% failure is pillar of 84% success. Not everything or idea can work in an environment, where numerous critical x-s can be there. We can not be 100% deterministic in our efforts and need to manage the learning curve. There are various approaches like PDCA, pilot projects, DoE to help you. But we have to be ready to face the uncertainty of the outcome with a clearer big-picture thinking. This needs courage-one of the best example is Thomas Alva Edison famously saying about his failed experiments, “I have not failed. I've just found 10,000 ways that won't work.”

?????????? ?????????????????? (Check Act Plan Do) will be very powerful approach for assessing Target vs Actual of the layout. Based on the gap found during check, actions can be planned for reducing/ eliminating deviations.

Today, before implementing any change in the real world, it's possible to simulate it virtually. Digital twin technology lets you create a virtual replica of your layout. You can experiment, analyze, and optimize within this virtual space without disrupting your current operations. This can help in foreseeing any potential issues and streamlining the design process.