Lean Layout

Case Study – Layout Workshop Our client is a family owned company with over 23,000 employees and a worldwide production footprint. Products vary from heating applications to geared motors.

Scope: As our client’s European production footprint expands, the senior executive team asked LMR to evaluate whether any consolidation of operations into existing sites could be achieved in order to reduce operating costs.

Application:
LMR proposed a Lean Layout workshop with key individuals including: production, production engineering, facilities and senior divisional representatives. The workshop was 5 days in duration held in a facility likely to receive additional capacity. The agenda for the 5 days consisted of general Lean awareness followed by some training in advanced Lean layout techniques used to formulate the Future State. Upon completion of the training, various production modelling sessions were held which could then be evaluated against the 3M principles (Muda, Mura, Muri) to determine the overall effect on unit cost of production and distribution costs. The top 3 proposals were then evaluated further using 1/50th layouts, high level standardised work, and production flow. Lastly, projections on the three scenarios were evaluated against fluctuations in demand to verify flexibility in production to meet customer demand.

Results:
Consolidation process met the needs of expansion with no further requirements for new premises.

ROI on LMR resource 140:1.