Plant Layout Optimization
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Plant Layout Optimization
Dating back to the firm’s industrial engineering heritage, Implementation Engineers specializes in optimizing plant layouts to address the evolving needs of clients in various industries. Clients often require plant layout optimization services due to factors such as significant growth, changes in production processes, technological advancements, and the need to improve operational efficiency. Inefficient plant layouts can lead to challenges such as disjointed product flow, extended lead times, excess Work In Process (WIP) inventory, and sub-optimized space utilization. By partnering with Implementation Engineers, clients can benefit from tailored strategies and solutions that enhance productivity, streamline operations, and maximize the utilization of their manufacturing facilities.
38% reduction in product touch points
40% more space in assembly, testing & machining
IX® in Action
Our client, a global leader in motion and control technologies, underwent significant growth and transformation throughout its history. As people, systems, and processes evolved alongside advancements in products, technologies, and equipment, the physical layout of their space no longer aligned with the demands of production or the intricacies of the products and processes involved. The increasing adoption of lean manufacturing practices further necessitated enhancements that could not be easily accommodated within the existing department and cell footprints. In light of these challenges, our client engaged Implementation Engineers to collaboratively explore opportunities for optimizing the reconfiguration of their plant layout and strategically positioning the facility for future requirements. Implementation Engineers devised a comprehensive macro-level strategy encompassing scheduling, inventory control, and material flow as a foundational framework to seamlessly integrate ongoing micro-level cellularization initiatives. Activities during IX® included:
- Observed and conducted operational interviews to understand the flow of information, material, tools, and people relative to each work center
- Executed a PR/PQ or similar product segmentation analysis to validate current value stream alignment or make recommendations for alterations
- Created product flow diagrams (spaghetti charts) for each product segment, including measurements for linear travel, lead time calculations, and touch point estimations
- Gathered utility provisional requirements for all applicable processes and equipment
- Collaborated on Critical to Satisfaction (CTS) elements for alternative layout assessment scoring
- Facilitated a 7-ways workshop with client personnel to generate multiple potential layouts and design the optimal future state layout based on CTS scoring
- Produced necessary CAD drawings to accurately depict movements and locations for all applicable furniture, equipment, and utilities provisions
- Identified production control or management changes required by the new layout
