CELLULAR LAYOUT OPTIMIZATION

PROJECT INCLUDES:

• Plant Layout Development

IMEG was hired by a pump manufacturer to develop and analyze layout options that would promote improvements regarding floor space usage, operator travel distance, and flow of materials. 

THE PROBLEM

cellular layout optimization

  • Congested work environment with three distinct workflow operations
  • No clear operator travel paths or work stations
  • Restricting storage methods
  • Non-conducive flow of material

proposed, material, plant, assembly

cell layout, assembly layout

THE PLAN

  • Field measure current plant layout and verify with AutoCAD model
  • Develop plant layout options and analyze the travel distance and floor space used
  • Perform WIP calculations to understand how much material is required to store lineside
  • Perform a walk-through of the most optimal layout with the operators
plant assembly analysis

THE RESULTS

  • Developed and analyzed 21 layout options to determine which was the most optimal for the flow of material
  • Current assembly space decreases from 36.5% to 21.5% of the total floor space, allowing an additional of an aisleway for improved material flow for pickers to kitting and packing stations
  • Unused space in the cell from 8.6% to 1.8%
  • Created a visual management system to provide improved organization
  • Proposed storage methods conducive to the calculated WIP quantities
  • Future state inventory quantities for the kits, vanes, and seals increase 11.16%, 13.14%, and 5.65% respectively
  • Designated a larger kit storage rack

plant, assembly, material

proposed cellular layout

proposed, material, plant, assembly

PLANT LAYOUT DEVELOPMENT CASE STUDIES

factory, facility
New Facility Design
Optimizing Current Facility Layout
Optimizing Current Facility Layout
office, plant
Office Layout Development
sketch, analysis, field measurement
AutoCAD Layout Development
plant
Finished Goods Warehouse Layout
Materials Supermarket Design
Materials Supermarket Design
Clean Room Layout Improvement
Clean Room Layout Improvement
factory
Food Manufacturing Optimal Layout
Equipment Upgrade Layout Update
Equipment Upgrade Layout Update
optimize
Cellular Layout Optimization
current layout development
Current Layout Development
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