Maximizing Efficiency With Lean Layout Design and Equipment Placement

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As operations leaders, we can easily recognize the importance of increasing our operational efficiency. Which is why we tend to always be on the lookout for ways to improve our processes and streamline our operations. One approach I've found to be effective is through implementing both lean layout design and equipment placement. I’ll dive into exactly what this means and how it can help us maximize efficiency.

Understanding Lean Layout Design

First, let’s talk about the basics of lean layout design. This concept may be new but really, it’s just applying the Lean Manufacturing principles to your workstation layout and workflow. The easiest way to think about this is thinking about the reduction of wasted movement. By reducing or eliminating unnecessary movement between workstations throughout your workflow, you will have significantly increased your overall operational efficiency.

If you need a refresher on the 8 Wastes, check out this previous article I wrote on How to Identify and Eliminate the 8 Wastes in Lean Manufacturing .

The Benefits of Lean Layout Design

We already covered the most obvious benefit, which is the impact on productivity and throughput but there are even more benefits that we can easily realize. Implementing this type of layout can also reduce the risk of accidents and injuries by creating a safer work environment for our team. Additionally, a well-designed layout can improve the flow of materials and reduce inventory levels, which can improve cash flow and of course, our bottom line.

Optimizing Equipment Placement

An equally effective strategy that can be used in combination with or as a standalone for maximizing efficiency is equipment placement. Proper equipment placement is all about avoiding common mistakes like placing equipment in areas where it could create bottlenecks or congestion. Think of too many pieces of equipment within a work cell without the proper amount of room to allow for the typical work in process materials or orders. Another often over looked consideration is making sure that equipment is placed in a way that allows for easy maintenance and repair.

Like with Lean Layout Design, we need to analyze our current equipment placement and identify any areas of waste. Looking for equipment that is not being used to its full potential or that is causing specific (and unintended) bottlenecks. Once these areas or work centers have been identified, we can rearrange our equipment to eliminate the waste and improve the workflow.

Additionally, we need to make sure that our equipment is placed in a way that minimizes travel time and distance for our team. We can do this in a variety of ways including creating work cells or considering the lean layout design process. By doing so, we can reduce the time our team spend moving around the facility and increase their efficiency. We should also consider the ergonomics of the equipment and make sure that it’s easy and comfortable for everyone to use.

Tips for Implementing Lean Layout Design and Equipment Placement

Implementing lean layout design and equipment placement can be a daunting task, but with the right approach, it can be highly effective. Here are three tips to help you get started:

1. Plan and Prepare Carefully: Before making any changes to your layout or equipment placement, take the time to plan and prepare carefully. This means analyzing your current processes and identifying areas for improvement. Consider the flow of materials and people, and think about how equipment can be positioned to minimize waste and maximize efficiency. Create a detailed plan that includes timelines, budgets, and responsibilities.
2. Involve Your Team: The people on our teams are the ones who will be using the equipment and working in the new layout, so it’s important to involve them in the process. Get their feedback and ideas for improving the layout and equipment placement. This will not only help you identify potential issues but also increase their buy-in and commitment to the new system.
3. Use Standardized Operating Procedures: Standardized operating procedures are a critical part of lean manufacturing and can be highly effective in improving efficiency and reducing waste. By creating standardized operating procedures, we can establish a consistent approach to work, minimize variation, and improve quality. This includes standardizing the position of equipment, tools, and supplies, as well as the sequence of tasks.

Final Thoughts

Maximizing efficiency with lean layout design and equipment placement is an important goal for any facility. By reducing waste and improving productivity, we can save time and money, while also creating a safer and more organized workplace.

That’s it for today.

See you all again in a couple of weeks!

Dave