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Plant Layout & Facility Design Seminar

Plant Layout & Facility Design

Structure & Infrastructure for Competitive Advantage

Plant Layout and facility planning is often the centerpiece of a Lean Manufacturing Strategy. In this seminar, participants learn a rationalized, structured approach that shows what to do, how, and when. By following the steps, you can design a facility to serve your company for many years.

The seminar covers all phases of facility planning and plant layout. Based on Mr. Lee's book, "Facility and Workplace Design",  participants learn about Site Plans, Macro- Layouts and Workcells in a practical, active, team-based environment.

The program includes many charts, forms, spreadsheet templates and a copy Mr. Lee's book. We can often incorporate examples from your own facility.

Program Summary

Format Onsite Workshop Who Should Attend?
Time 3-Day


Industrial Engr

Manufacturing Engr

Facility Planners

Production Supervisors

Cost $6500 (Includes Travel)
Participants 5-35
Next Step Call us at 816-931-1414

Participants Will Learn...

Organizing The Plant Layout Project

  • Five Symptoms of a sub-optimum plant layout.

  • How to organize facility planning.

Macro-Layouts - Strategy In Concrete & Steel

  • How the Macro Plant Layout implements a Manufacturing Strategy.

  • Four Fundamental Elements: Space Planning Units, Affinities, Space and Constraints.

  • What information to acquire, how to get it, and what to do with it.

  • Why up to 70% of your space may currently be wasted!.

  • How to avoid politics, conflict, and frustration.

  • How to measure and analyze material flow.

  • Six ways to calculate space-- for now and the future.

  • Constraints-- bringing reality into your plans.

  • Selecting the best facility plan.

Micro Layouts & Workcell Design

  • Four Essential steps to workcell design...proven effective in companies worldwide.

  • Three techniques to identify Product Families.

  • Six methods of work balance.

  • Why the workcell layout is NOT the first issue to tackle.

Master Site Planning-

  • How to plan a site for years, decades, even a century!.

  • About Focused Factories and how they affect site planning.

  • Strategies for expansion that make full use of the land and infrastructure.

Workstations & Ergonomics

  • How to avoid Carpal Tunnel Syndrome and other Repetitive Stress Disorders.

  • Principles of Motion Economy and Ergonomics and how to apply them.

Program Outline

1. The Challenge Facility Planning

  • Complexity, Workflow, Cost

  • Approaches To Facility Planning

  • Levels of Space Planning

  • Elements of A Spaceplan

2. Site Planning

  • Structuring The Planning Project

  • Phasing Site Plans

  • Development Strategies

  • Case Study-- High Plains Implements

  • Data Acquisition

  • Products & Volumes

  • Operations Strategy

  • Dimensioning The Site

3. Macro Layouts

  • Structuring The Project

  • Products & Volumes

  • Space Analysis

  • Processes

  • Scheduling

  • Physical Infrastructure

  • Organization & People

  • Manufacturing Strategy

  • Focused Factories & Lean

  • Define Space Planning Units

  • Material Flow

  • Non-Flow Affinities

  • Configuration Diagrams

  • Future Space

  • The Layout Primitive

  • Constraints

  • The Macro Layout

  • Material Flow

  • Weighted Factor Decisions

  • Layout The Plant

4. Micro Layouts & Workcells

  • Five Steps To Effective Workcells

  • Selecting The Products

  • Engineering The Process

  • Selecting Infrastructure

  • Work Balance

5. The Sub Micro Layout & Workstation Design

Principles of Ergonomics

Principles of Motion Economy

6. Implementing Facility Plans

Levels of Planning

Layout Procedure


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