Plant Layout & Facility Design

Plant Layout and facility planning is often the centerpiece of a Lean Manufacturing Strategy. In this seminar, participants learn a rationalized, structured approach that shows what to do, how, and when. By following the steps, you can design a facility to serve your company for many years.

The seminar covers all phases of facility planning and plant layout. Based on Mr. Lee's book, "Facility and Workplace Design",  participants learn about Site Plans, Macro- Layouts and Workcells in a practical, active, team-based environment. The program includes many charts, forms, spreadsheet templates and a copy Mr. Lee's book. 

Phone to Schedule

816-931-1414

1. The Challenge Facility Planning

Complexity, Workflow, Cost

Approaches To Facility Planning

Levels of Space Planning

Time Phasing The Design Levels

Elements of A Spaceplan

2. Site Planning

Structuring The Site Planning Project

Phasing Site Plans

Development Strategies

Case Study-- High Plains Implements

Data Acquisition

Products & Volumes

Operations Strategy

Dimensioning The Site

3. Macro Layouts

Structuring The Project

Data Acquisition

Products & Volumes

Space Analysis

Processes

Scheduling

Physical Infrastructure

Organization & People

Manufacturing Strategy

Developing A Strategy Statement

Focused Factories

Lean Manufacturing

Layout The Plant

Defining Space Planning Units

Material Flow Analysis

Non-Flow Affinities

(Macro Layouts Continued)

The Configuration Diagram

Estimating Future Space

The Layout Primitive

Identifying Constraints

The Macro Layout

Selecting the Best Option

Material Flow Diagrams

Weighted Factor Decisions

4. Micro Layouts & Workcells

Five Steps To Effective Workcells

Selecting The Products

Intuitive Grouping

Production Flow analysis

Coding & Classification

Engineering The Process

Process Charting

Calculating The Number of Workers

Lot Sizing

Selecting Infrastructure

Scheduling

Containers

Compensation

Supervision

Work Balance

5. The Sub Micro Layout & Workstation Design

Organizing The Project

Principles of Ergonomics

Principles of Motion Economy

6. Implementing Facility Plans

Organizing The Plant Layout Project

• Five Symptoms of a plant layout that doesn't work.

• How to organize facility planning.

Macro-Layouts - Strategy In Concrete & Steel

• How the Macro Plant Layout implements a Manufacturing Strategy.

• Four Fundamental Elements: Space Planning Units, Affinities, Space and Constraints.

• What information to acquire, how to get it, and what to do with it.

• Why up to 70% of your space may currently be wasted!.

• How to avoid politics, conflict, and frustration.

• How to measure and analyze material flow.

• Six ways to calculate space-- for now and the future.

• Constraints-- bringing reality into your plans.

• Selecting the best facility plan.

Micro Layouts & Workcell Design

• Four Essential steps to workcell design...proven effective in companies worldwide.

• Three techniques to identify Product Families.

• Six methods of work balance.

• Why the workcell layout is NOT the first issue to tackle.

Master Site Planning-

• How to plan a site for years, decades, even a century!.

• About Focused Factories and how they affect site planning.

• Strategies for expansion that make full use of the land and infrastructure.

Workstations & Ergonomics

• How to avoid Carpal Tunnel Syndrome and other Repetitive Stress Disorders.

• Principles of Motion Economy and Ergonomics and how to apply them.