How do you optimize the layout of a manufacturing system? (2024)

I would offer another key objective to consider: meeting the takt time. Takt time is the rate at which you need to complete a product to meet customer demand. Over- or under-producing can each be detrimental to the business.

Logistics consideration is an important factor in designing a factory floor. It is very crucial to decide early on the inventory levels in the warehouse and on the shop floor, to decide the space sharing for factory machines & and warehouse. The method & and routes of safe transportation of goods from the warehouse to the shop floor, and within the shop floor machines/units, such as the use of fork lifter, jig crane, and tow truck for material movement. Next is deciding on the balanced space allocation for the Work in process and the finished product. which is an 'egg or chicken problem' for many industries in times of uncertain demand. Once you have got the logistics correct then you are ready to build an optimized shop floor layout.

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A common mistake in this step is to ignore material handling routes and methods (conveyor, hand cart, pallet jack, forklift, etc.), and and line-side inventory needs to fully support production. The machines and other equipment in production area must obviously be considered, but so too must the way that materials get into and out of each area, and the space needed and presentation method of the materials to the operators in those areas. These factors can significantly affect the layout when included. But if they aren't included, then the anticipated results of the new layout will likely be less favorable than predicted because of the inefficiency of materials movement into, through, and out of each area.

In flow or batch manufacturing, (operation time + transfer time)÷(number of stations per operation)= yield% * Takt time. (One assembly station installing multiple parts is considered one operation in this case. Also, the time it takes for a machine to make a part is one operation time.) You need to solve for number of stations. If you don't consider all elements of the equation, you will have waiting or WIP, both are excess costs.

DFM is critical to the process, it's difficult to start planning a production process until the product is relatively stable and meets all product objectives, including DFM. Once those boundaries are established planning can start.

Optimizing the layout of a manufacturing system involves considering factors like workflow efficiency, space utilization, and resource allocation. Conduct a thorough analysis of production processes, minimize bottlenecks, and arrange workstations logically to reduce material handling. Utilize tools like process flow diagrams and simulation software to model and test different layouts. Continuous improvement and flexibility in design are key for adapting to changing production needs.

Anticipate where the product can/will become mixed model. Keep a "node" mindset when laying out the big pieces. To the extent you can, keep things mobile, modular and off-the-shelf until the product is mature enough to command tailor made fixtures, equipment etc. Scorecard your requirements. Often times concessions must be made that mean you can't design it the way you like it and that super cool thing you want to do just isn't going to happen this round. Trust me there will be other opportunities, and that great idea's time will come. Save the real creative solutions for the things you just aren't going to find an amazon fix for.

Before you can generate layouts, you must have a general idea of the assembly order and know the time it takes to assemble each piece to put each subassembly and the whole product together. You must also take into account the non-flexible portion of assembly order. These items let you determine the layout based on Takt time. It will guide you in what simultaneous operations - (off-line subs) you can do and how you can create different layouts. Each station cycle time plus transfer time needs to equal Takt time. It's a large simultaneous equation with constraints, iteration, and potentially multiple optimum answers. It's a scientific art I don't think AI can yet answer.

If you are using Lean methodologies to improve the flow and cycle times, your manufacturing system may need continued fine-tuning as you meet the performance goals and contemplate raising the performance bar. In Lean manufacturing, we used the term "creativity before capital" to ensure we are cost minded in implementing solutions that may need to be scrapped after a few production runs, due to continuous improvements and better solutions. Lean is a journey and an attitude of "one and done" does not hold up if you're striving to be best in class in manufacturing.

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Changeover: Don't overlook this huge factor! It can be a major source of downtime and lost productivity. If you don't consider changeover requirements early in the design process, you could end up with a production system that has a significant % reduction in OEE. Here are some tips for reducing changeover time: 1. Locate tools and materials near the point of operation. 2. Reduce the number of tools and steps required. 3. Design the layout for easy access for maintenance personnel. 4. Consider redundant designs of sub-systems. By following these tips, you can reduce changeover time and improve OEE. Bottom line: Don't overlook changeover! It's a huge factor that can have a significant impact on your production system.

Additionally, it can be helpful to mark out the placement of each machine, rack, WIP location, etc. with floor tape that is not too difficult to remove when implementing the new layout. Once the area is in production and changes are made to optimize production, the tape can be removed and the floor markings can be made more permanent to aid in 5S and creating a visual workplace.