CELLULAR LAYOUT OPTIMIZATION

workstation layout

SERVICE AREA:

IMEG partnered with a pump manufacturer to implement a cellular layout optimization initiative aimed at improving material flow, enhancing workflow efficiency, and maximizing production space utilization. This project focused on developing a cellular manufacturing layout that aligned with lean production principles and supported long-term operational scalability.

THE PROBLEM

cellular layout optimization

Congested work environment with three distinct but inefficient workflows
Undefined operator travel paths and disorganized workstation layout
Ineffective storage methods disrupting material handling within manufacturing cells
Reduced productivity due to poor floor space efficiency and work cell arrangement

THE PLAN

To address these challenges, IMEG deployed a structured approach to cellular production layout improvement:

Conducted field measurement of the current layout and verified with AutoCAD model
Developed and compared 21 cellular manufacturing layout options designed to optimize operator travel paths, workstation flow, and floor space utilization
Performed travel distance analysis and workstation floor space analysis analysis for each configuration
Conducted a WIP (Work In Progress) control assessment to ensure optimal material handling in the work cells
Implemented a visual factory layout strategy to improve clarity, communication, and cell-level organization
Facilitated walk-throughs with production operators to validate the ergonomic design of each proposed layout