IMEG was hired by a pump manufacturer to develop and analyze layout options that would promote improvements regarding floor space usage, operator travel distance, and flow of materials.
THE PROBLEM
cellular layout optimization
Congested work environment with three distinct workflow operations
No clear operator travel paths or work stations
Restricting storage methods
Non-conducive flow of material
THE PLAN
Field measure current plant layout and verify with AutoCAD model
Develop plant layout options and analyze the travel distance and floor space used
Perform WIP calculations to understand how much material is required to store lineside
Perform a walk-through of the most optimal layout with the operators
THE RESULTS
Developed and analyzed 21 layout options to determine which was the most optimal for the flow of material
Current assembly space decreases from 36.5% to 21.5% of the total floor space, allowing an additional of an aisleway for improved material flow for pickers to kitting and packing stations
Unused space in the cell from 8.6% to 1.8%
Created a visual management system to provide improved organization
Proposed storage methods conducive to the calculated WIP quantities
Future state inventory quantities for the kits, vanes, and seals increase 11.16%, 13.14%, and 5.65% respectively
