Operational layout is a key factor in process efficiency. We provide services for operational layout design and redesign, identifying opportunities for improvement and optimization of operational and supply flows, as well as space optimization. A well-designed layout optimizes resources, reduces waste, and enables significant competitive advantages.
Consultancy service in layout design and redesign projects
Lean layout design approach
Organized spatial dispersion of the various elements that make up a value generation system, consisting of multiple processes and functions, within a finite three-dimensional space. System elements include, among others, equipment, materials, people, information, safety, and communication. The objective of the layout is to create a configuration that enables the efficient execution of activities and facilitates interaction among system elements, maximizing space utilization and ensuring a safe and ergonomic working environment.
The layout influences the performance and operational competitiveness of an organization
A poorly sized or organized layout has a detrimental effect on operational performance, negatively impacting economic and operational profitability, and therefore reducing competitiveness.
A layout can be a source of inefficiencies and waste, which, when integrated over time, can have a significant impact on productivity. In addition to issues related to safety, a layout can either mitigate or enhance risk situations. It also influences process time. A well-defined internal flow, aligned with lean management and kaizen principles, definitely contributes to achieving shorter lead times. Shorter lead times enable an organization to present a more effective and competitive value proposition to the market compared to its competitors.
The effect of an outdated layout on the major performance inhibitors
Critical factors in layout design
Drivers for the layout design process at Leanked
Space and waste
Preparing the space for potential expansion or changes in demand. Designing for flexibility and promoting efficiency and waste reduction.
Flow and movement
Layout designed to promote and facilitate seamless flow within and between processes and operations, without obstacles, constraints, or crossovers, across the entire value chain.
Creating conditions for the proper handling and movement of raw materials, work-in-progress (WIP), finished products, containers, and equipment. Ensuring simple, organized, structured, and efficient flows.
Signalling and marking the placement of machinery and equipment, logistics and personnel circuits, storage areas, process and machine boundaries, etc.
Receiving and shipping
Properly sizing, in terms of capacity and operability, the receiving and shipping activities.
Installing a layout that ensures the smooth operation of operations, with full safety for people and in compliance with health, safety, and environmental regulations.
The layout should enhance ease of communication between activities, functions, employees, and stakeholders (customers and suppliers).
Promotion and positioning
Facilities serve as a showcase to the outside world and can reinforce positioning, identity, and brand. External visits from clients, suppliers, financiers, investors, the community, etc., are frequent.
Motivation and satisfaction
Promoting employee satisfaction and motivation by providing better working conditions. Relevant aspects such as clear walls, windows, natural light, etc., positively influence employee productivity.
The value proposition of Leanked for layout projects
Lean layout design approach
Leanked, through its team of experts in lean manufacturing and kaizen methodologies, along with their expertise in operations management and industrial engineering, offers a service focused on problem-solving related to layout design. The primary goal is to enhance the positive impact of the layout on the overall operational performance of an organization by presenting value-added alternative solutions. A well-designed layout contributes to the efficiency and effectiveness of processes, promoting the ideal relationship between people, materials (raw materials, work-in-progress, and finished products), and equipment at the lowest cost and time possible, while ensuring safety, communication, and motivation aspects.
This service provided by Leanked follows a tailored approach. The Leanked team is capable of addressing the complexity of the problem and adapts the capability and capacity of their service to the specificity, size, and structure of the client’s needs and challenges.
Range of proven tools and methodologies applied by Leanked in layout projects
Lean layout design, consultancy approach lean, kaizen and IEM
Process Mapping and Analysis
Structured and guided interviews
Shareholders and stakeholders
Systematic layout planning
The Leanked's offering for layout projects
Lean layout design
New facility design
Design of new facilities and their respective layouts.
Layout design for existing facilities and spaces.
Redesign of layouts
Redesign of the implemented layout to enhance operational performance.
Optimized and balanced design of assembly lines.
Layout assessment and analysis
Structured assessment of installed layouts, identifying strengths, weaknesses, and improvement opportunities.
Optimized and balanced design of manufacturing cells.