LEAN PLANT LAYOUT

PHASE 1

PLANT LAYOUT
Any arrangement of machines and
facilities is layout. F.G. Moore

TraditionalLayoutTypes
FUNCTIONAL LAYOUT
MACHINES HAVING SAME FUNCTION ARE
GROUPED TOGETHER

LINE LAYOUT
SINGLE LINE FLOW OF MATERIAL UNDERGOING
DIFFERENT PROCESS

FIXED POSITION LAYOUT

PRODUCT IS EXTREMELY LARGE

COMBINATION LAYOUT

USES BOTH LAYOUT AS IT PRODUCES

COMPONENTS FOR THE PRODUCT
TOO.

CELL LAYOUT
VARIOUS PRODUCT IS DIVIDED IN TO
PRODUCT FAMILY AND MADE TO PASS
THROUGH PROCESSES WHICH ARE
COMMON.

Backgroundofcompanies

ArielTransformersCompany
(ATC)establishedin1999inUAE,
offershighqualitytransformerwhich
catersvarietyofelectricpowersector
distribution,hasexportedmorethan
24,250transformer/package
substationsincountrieslikeSouth
America,Europe,Africa,MiddleEast
andEastAsia.

OnceasmallfamilybusinessThe
CanvasCorporationafter40years
isnowoneoftheleadingbusiness
corporationshavingaglobalinfluence
hasspreadinfieldsofAutomotive,
Construction,Energy,Engineering,
andothers.TheCanvas
Corporationhasnowacquired
ArielTransformersCompany.

ATCplantsituatedinAX1wasproposedtobemovedinAX2plantofThe
CanvasCorporation

Method
Meetinganddiscussionswiththeleadershipteam.
Facilitytourandshopfloorstudies
GembaObservations.
Pastdemand,capacityanalysis
AssessmentofPlantdimensions&infrastructureandData
collectionofrelevantmetrics
Brainstorming

LeanPlantLayout
LeanPlantLayoutisaplantlayout
withoutthe7wasteofleanandwithgood
principlesofaplantlayout

ProjectMission
Suggestifitspossibletoentiretransformersplant
(ATC)hadtobecompletelymovedfromoneplant
locationintoanotherplant(TheCanvas
corporation)andalsotomakeitlean.

FourTypesOfLeanPlantLayoutSuggested
1.Plantlayoutdesignedlikecurrentfacilities
ThisPlantLayoutwasdesignedbyjustplacingtheexactplantintheother
plant.Nochangesweremade.Analysisfurthershoweditwas50%less
efficientthenothermanufacturers

2.Plantlayoutdesignedwithmaximumcapacity
ThisPlantLayoutwasdesignedbytakingmaximumutilizationofthe
machineswithnoovertime.Thisplantlayoutis75%moreefficientthen
abovelayout

3.Plantlayoutdesignedforcurrentdemand
ThisPlantLayoutwasdesignedwasleanandaccordingtocurrent
demandsandreducedthedeliverytimeissuesto10%

4.Plantlayoutdesignedformaximumdemand
ThisPlantLayoutwasdesignedbytakingmaximummaximumdemand
whichwas100%morethancurrentdemand.

BenefitsOfAllthelayouts

35 %

Reductionin
leadTime

Higher
Throughput

Reduction
inManpower

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