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Planning and Designing a Lean Manufacturing Facility
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HISTORY• Founded in 1898• 100% employee owned
STRENGTH• $2.0B sales• EPC capability
STABILITY• Growth during recession • < 4% employee turnover
SERVICE• 85%+ repeat client base• Relationship driven business model
Our Mission: Make Our Clients Successful
Company Profile
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• From start-to-finish, we provide:– Project Development & FEP:
• Site development• Environmental assessment &
permitting• Utility interconnection• Conceptual designs • Master planning• Technology selection• Estimating• LEAN | Six Sigma Design
– Plant & Site Support• Small capital projects• Troubleshooting• Project support• Field engineering
Full-Service Execution
– Engineer, Procure, & Construct• Detailed design• Project procurement &
expediting• Schedule & cost controls• Subcontractor sourcing &
prequalification• Safety & health training• Start-up & commissioning
Click to edit Master title styleLean Six Sigma
• Lean Six Sigma (LSS) has historically been seen as a quality and efficiency tool used on the manufacturing floor
• Many manufacturing companies have begun to incorporate LSS methodologies into the design/ renovation of their facilities – Reduce Square Footage– Reduce Capital Construction Cost – Increase Efficiency– Optimize People & Product Flow– Leverage New Technologies
Click to edit Master title styleTypical Process
• How many square feet do we need?• How big will the building be?• What is our budget to do this project?• What utilities are required?• Who is going to manage this project?• How quick can we get a layout done?
Are These the Right Questions??
Click to edit Master title styleDesign for the Process
The Value Stream• People Flow• Material Flow• Material Management• Production of Goods• Management of Finished Goods• Information Management• Waste/Dunnage Management
Click to edit Master title styleThe Design Process
• Design the Building or Space Around the Process• Collect Facility & Process Requirements• Select a Site
– Cause & Effect Matrix• Generate Conceptual Layouts Based on Data• Select a Layout and Simulate• Phased Design to Meet rate Increases• Estimate Cost• Build Schedule/Phase Construction
Click to edit Master title styleThe Design Process – Data Collection
• Data Collection– Cycle Times– Work Schedules– Rate Demand– Takt Time
• Create Process Maps– VSM– Swim Lane– Spaghetti
• Collect Customer Requirements– Financial Requirements– Facility Goals– Quality and Efficiency Targets– Compliance & Permitting
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Click to edit Master title styleAerospace Coating Facility
Process• Teamed with Industrial & Manufacturing Engineers• Mapped the Process• Improved the Process Flow• Generated the Process Layout• Integrated new technologies• Developed the Building Layout & Initial Design• Simulated the Process in the BuildingResults• Reduced Facility Footprint by 20% from Original Concept• Developed a Phased Build Plan for Production• Reduced Anticipated Capital Spend by 25%• Simulation Identified Areas for Improvement
Click to edit Master title styleProjectile Manufacturer
Process• Created Manufacturing Cells• Developed Single Piece Flow• Generated the Cell Process Layout• Integrated Automated Material Handling• Developed the Building Layout & Design• Simulated the ProcessResults• Reduced Facility Footprint by 10% from Original Concept• Determined a Phased Build Plan to Support Increased Production• Reduced Cycle Time from 9 Days to 1 Day
Click to edit Master title styleOil & Gas Supplier
• Process Design • Reduced Square footage by 15%• Manufacturing Process Design
• Automated Material Handling• Robotic Assembly & Machining• Robotic Machine Tending
• Automated material handling integrated into the manufacturing process
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