![]() In the past, plant layout modifications were triggered after there was a need for change, and companies grew in a disorderly and disorganized way. Moreover, this decision can be affected by several factors such as the kind and the complexity of the product to be made, the quality of the raw materials, the complexity of the manufacturing process, the available shop floor area, and the arrangement of departments constituting the production process among other decisions ( De Carlo et al., 2013 Flessas et al., 2015). Therefore, applying LM principles in plant layout designs is a key strategy for surviving in competitive markets ( Zhang et al., 2019 Kovács, 2020).ĭetermining the layout of a manufacturing system might be challenging since the most efficient shop floor arrangement depends on unequal requirements of different natures and departments within a facility ( Liu & Liu, 2019). Regardless of the company’s size, its “layout design” is decisive for achieving greater efficiency in materials handling and, consequently, for reducing manufacturing costs (i.e., material handling costs). One of the main applications of LM concerns “plant layout optimization”. LM has proven to be an effective operations management strategy, which helps companies to adapt their value chain to market demand through continuous improvement ( Henao et al., 2019). Keywords: Lean manufacturing+ Plant layout design+ Systematic layout planning.Īmong the strategies to reach customers’ expectations and to increase competitiveness in the modern market, Lean Manufacturing (LM) stands out as it provides greater flexibility, quality, and responsiveness to a production system ( Bai et al., 2019). ![]() This paper provides an original industrial case study with valuable insights for the adaptation of the SLP model to reformulate plant designs. ![]() Some of the expected results include costs reduction handling, organic growth elimination, unnecessary movements reduction and less arrangement adjustments. Information is collected through multiple site visits and semi-structured interviews with the company’s key staff, as well as examination of relevant company documentations. ![]() To showcase the application of LM on plant layout design, an ABC Industries’ facility is selected. The obtained results encourage assuming its transferability to similar situations than textile industry. This paper provides an original industrial case study with valuable insights for practitioners interested in layout redesign. This research proposes a new facility layout for an Indian textile company based on guidelines for Systematic Layout Planning (SLP) and Lean Manufacturing (LM). ![]()
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