| COMMON
PROCESS FLOWS
in
Lean Manufacturing |
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| THE LEAN OFFICE |
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Lean isn't just for the manufacturing floor. Companies today are using lean throughout their operations and improving the entire value stream.
Web-Based Training for the Lean Office
COMING THIS SUMMER:
The Lean Office | |
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Greetings!
This month we are focusing on Lean Layouts - one of several important components of Lean Manufacturing.
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Creating Lean Layouts |
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An effective process flow and an efficient layout are at the heart of lean manufacturing. Good layouts arrange the process steps in a natural flow order, link process steps to minimize cycle time and travel distance, eliminate crossover points and simulate a continuous flow process by putting internal customers and suppliers next to each other.
Four of the more common layout patterns are:
- U-Shaped Flow
- Straight-Through Flow
- L-Shaped Flow
- Comb & Spine Arrangement
Which layout configuration is best for your operation? The choice depends on process flow considerations, physical constraints of the site and support system concerns. |
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PRODUCT FOCUS: Lean Manufacturing |
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If you want to learn more about Lean Process Layouts, we recommend that you check out our Lean Manufacturing course. This is a comprehensive course that covers all aspects of lean manufacturing including process layouts.
Lean Process Layouts are specifically covered in two lessons in this course: Unit 3, Lesson 2, Data Drives Lean, sets the stage for developing layouts. Effective process layouts can only be developed if solid data about the process flow are available. In Lesson 3, Layout Options, common process layout configurations that arrange flow patterns of process steps in a natural flow order are examined. All flow patterns link process steps to minimize cycle time and travel distance and simulate a continuous flow process by putting internal customers and suppliers next to each other. Then, factors that will impact the selection of the best flow option are explored.
NOW AVAILABLE IN SPANISH!
To learn more about this course or to take a free lesson to see if it is right for you, click here. |
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Six Steps to Lean Layouts
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1. Identify Product Families
~~ Use a Product Family Matrix to identify product families. The Matrix matches process steps and products. Groupings of common process steps are the product families.
2. Map the Value Streams
~~ Mapping the value stream by product family is less daunting than mapping the value stream for the entire facility.
~~ Value Stream Maps create a visual of the workflow and help organize process data for further analysis.
3. Analyze Data
~~ Time studies, equipment loading, cycle times, takt times, staffing requirements, yields, lot sizes, and kanban sizes are some the data to be analyzed or developed.
4. Develop the Macro Workflow and Layout Options
~~ Items to take into account when developing macro workflow options include: Cubic feet (bulk) handled, use of shared equipment/resources, use of feeder cells, impact of purchased (offsite) services, location of entry and exit points, building height and floor loading, location of monuments, utility (power, process water, compressed air, steam) needs, environmental discharges, location of overhead cranes/hoists, aisleways/accessways and maintenance access.
5. Select the Best Option
~~ Compromises will ALWAYS have to be made. The best option should be the option that best meets your predetermined criteria.
6. Develop the Micro Workflows and Layouts
~~ When finalizing the micro layouts, look at plans for balancing lines, the use of kanbans, work station organization, and overall work area concerns on personnel safety and environmental exposure. | |
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Thanks for your continuing support and interest in our products!
Sincerely,
Robin McDermott
Resource Engineering, Inc. |
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