![]() Lean layouts are more likely to combine processes horizontally across the factory, compared to vertical process departments like silos in a traditional facility layout. Lean plant layout focuses on value streams, all value-added steps from raw materials until the delivery to your customer. This leads to high levels of work-in-process inventory and long lead times. To make production more economical, work is often done in batches (in the name of economic batch quantity). Usually, there are walls between these different workshops, and materials are transported between department by forklifts. A typical traditional machinery factory might be separated into workshops of cutting, fabrication, machining, and assembly. Similar machines are grouped into functional work centers or workshops. Traditional plant layout focuses more on process-based departments. There are a variety of factors that differentiate a Lean plant layout from a Traditional plant layout. What are the Differences Between a Traditional and Lean Plant Layout? If you are designing or redeveloping your operations a Lean plant layout will help you create a more flexible and efficient use of your space. Lean facilities create a seamless flow for material and information, minimising handling time and effort, saves on floor space, shortens lead times to customers, increases productivity and quality. As you may know, Lean eliminates wastes, and deliver values to your customers with lower costs, high quality, shorter lead time, safer and high morale. Here at TXM, we call a good plant layout, one that applies Lean principles to create a Lean plant layout. These views will change depending on the type of layout you wish to achieve. When talking about plant layout there are always varying views as to what is a ‘good’ plant layout. It will not only have a direct effect on the efficiency of your operations but also affect the total operation of your company, including the production processes, inventory, dispatch, and administration. Having an effective plant layout is one of the keys to success in factory management. Why it’s important to have a Lean Plant Layout?.What are the differences between a Traditional and Lean Plant Layout?.If you are new to Lean or heard of it and maybe exploring your options, we’ve broken down this article into 4 parts which you can jump right into after clicking on the links below: An unpleasant work environment with too much finger-pointing, blame, and excuses.Too much fire fighting and fixing problems.At capacity with bottlenecks in production.Many plant managers today experience the same pain points that were common years ago: In fact, our lean consultants are yet to find any plants where improvements in layouts can’t make positive and lasting changes. Lean Thinking has evolved over the years and while the latest buzzword is Industry 4.0, improving plant layouts using Lean methodologies can hugely improve plant efficiency.
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