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Layout design

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

Layout definition

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The effect of an outdated layout on the major performance inhibitors

The effect of an outdated layout on performance inhibitors is significant. An outdated layout can contribute to various performance inhibitors, such as in variability; Inflexibility; Waste; and Paradigms.
By implementing a well-designed layout that promotes lean principles, such as smooth flow, minimized transportation, and reduced handling, organizations can mitigate waste production and improve overall operational efficiency.


An inefficient layout can lead to increased variability in processes, resulting in inconsistent output and lower quality. Uncertainty regarding the final outcome of each process and the final output increases. Uncertainty can also arise due to factors such as inefficient material flow, inadequate allocation of resources, and lack of standardized processes.


An outdated layout can amplify waste production (muda). When elements within a layout are disorganized or inefficiently arranged, it can lead to unnecessary movement, transportation, waiting times, and excessive inventory. These factors contribute to various forms of waste, including overproduction, excess inventory, unnecessary motion, waiting, and defects.


A poor layout reduces the organization's ability to adapt to changes in demand and production. The lack of flexibility resulting from an inadequate layout makes it difficult to make quick and efficient adjustments to meet changes in customer and market needs and demand. This can lead to delivery delays, excess or insufficient inventory, operational inefficiencies, and missed business opportunities. A well-designed and flexible layout is essential to enable an organization to respond swiftly and effectively to changes, thereby maintaining its competitiveness and ability to meet market demands.


A bad layout can reinforce outdated beliefs and ways of thinking within an organization. It may hinder the adoption of new and innovative approaches, as employees become accustomed to inefficient processes and resist change. This can create a culture of complacency and obstruct the organization's ability to adapt to new challenges and market dynamics. By implementing an optimized layout and promoting a culture of continuous improvement, organizations can challenge existing paradigms and foster a mindset of innovation, agility, and adaptability.

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.

Materials handling

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.

Space marking

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

Gemaba walk

Gemba walk

Mapeamento de processos

Process Mapping and Analysis

Entrevistas estruturadas e orientadas

Structured and guided interviews

Shareholders and stakeholders

CAD, desnho tecnico


Tecnicas de simulação


Systematic layout planning

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

Layout design for existing facilities and spaces.

Redesign of layouts

Redesign of the implemented layout to enhance operational performance.

Assembly lines

Optimized and balanced design of assembly lines.

Layout assessment and analysis

Structured assessment of installed layouts, identifying strengths, weaknesses, and improvement opportunities.

Manufacturing cells

Optimized and balanced design of manufacturing cells.

Please request more information about our layout design service.