Layout & Flow Improvement
Recovering 50% of the floor space while doubling assembly output
Redesigning a component-assembly area around one-piece flow.
Previous hands-on production-engineering work; not presented as a FlowForge customer engagement.
- Less production floor space required
- 50%
- More output from component assembly
- 100%
Both results from the same component assembly area redesign.
The initial condition
The component assembly layout was not arranged to support a clean one-piece production flow. The physical arrangement needed to follow the actual sequence required to build the units.
What changed
The component assembly area and its machines and workstations were rearranged so the product could move through the process in a one-piece flow sequence.
- Position the machines and workstations around the unit-building sequence.
- Arrange movement through the area so the physical layout supports the order in which the work occurs.
The result
The redesigned component assembly area required 50% less production floor space and increased output by 100%. Both results belong to this same component assembly redesign.
The production lesson
A layout should follow the production process. Positioning equipment according to where it historically fitted can create extra movement, excess space and poor visibility of the process.
One-piece flow is not achieved by drawing arrows on a layout. The physical process has to make the intended sequence easy to follow.
Review the work in your operation
Related services