Case Study, Local Manufacturer Gains 30% More Workspace with Lean Layout Redesign

Local Manufacturer Gains 30% More Workspace with Lean Layout Redesign

Background

A local millwork shop with 30+ machines produced doors, cabinets, and longbows. Finishing operations and finished products had been moved to a different building to make room for new coffee processing facilities. The remaining space was still congested, so they requested help to design and optimize the layout.

Solution

The current space was already over 100% utilized, so two expansion sections were added to double the available square footage. One section was needed to support additional machines and materials, the other to move Finishing operations into the same building and eliminate extra handling. After establishing primary process flows, equipment was categorized by processing step and a U-shaped production cell was chosen for the layout. This type of cell works because the raw materials and finished goods would share the same dock door, while minimizing transportation and handling.

Results

Redesigning and increasing the available space reduced space utilization from over 100% to 70%, while allowing finishing operations to move back into the building. The new layout also optimized placement of wood bins, tools, hardware and finished products to improve safety and efficiency.

Want to see results like this at your company? Contact our team to learn more.

Innovative insights delivered to your inbox once a month

We hate spam and will never share your information. You can unsubscribe at any time.

Newsletter Sample

NEWSLETTER SIGNUP

Corporate SG&A Assessment Positions Leading Company for Future Growth

CASE STUDY, ASSESSMENTS

Private Equity Group Requests Help with Inventory Management and S&OP

CASE STUDY, OPERATIONS

Operations Consulting

We have consulting experience with engagements as diverse as mergers and acquisitions, operations strategy, supply chain acceleration, shop-floor process improvements, and call center efficiency improvement.

Word Puzzle Challenge

How much do you know about Operational Excellence?

Play our continuous improvement version of a popular word game, with a new word every day. Can you guess today’s word?

OPERATIONAL EXCELLENCE WORD PUZZLE

Assessments

Assessments are customized to meet your goals, leveraging our frameworks and knowledge of best practices from years of industry experience. Recent work has been in financial services, insurance, healthcare, manufacturing, and supply chain.