Proper layout design incorporates the placement of offices and equipment in a manner to minimize operational costs while maintaining employee safety.
Cellular manufacturing and Systematic Layout Planning (SLP) are two tools that can be used to accomplish this goal. Productivity Solutions’ comprehension of the cost impact of proper layout designs was demonstrated with their research and publications related to Group Technology techniques back in 1991. This was before being fully accepted by industry.
Layout Design Capabilities
- Cellular Manufacturing / Group Technology Techniques
- Systematic Layout Planning (SLP)
- Warehouse Design
- Material Handling System Design
- Ergonomic – Work station design
Fiberglass Panel Manufacturer for the Recreational Vehicle Industry
Sprays chopped glass and polymers on molds, cuts and packages large panels.
- Designed facility layout and capacity analysis of a $14 million building expansion to double production.
- Performed capacity calculations to specify material handling equipment requirements.
- Provided and trained employees on procedures, production target tables and operator utilization calculations for analyzing and identifying process improvements.
- Performed a labor analysis the resulted in a 25% increase in production efficiency. and capacity 25% by identifying and eliminating non-value added steps associated with labor tasks.
Projection TV Lens Manufacturer
Manufactures and assembles several million lens assemblies annually from glass blanks, injection molded lenses and components.
- Performed a 60,000-sq. ft. warehouse layout design to minimize floor space requirements, material handling costs and inventory carrying costs. This was done by performing a complete material flow analysis.
- Provided spreadsheet models for re-calculating reorder-point levels and inventory turns to minimize inventory-carrying costs of different product forecasts.
Glass Company
Manufacturer of glass blanks for microchip etching lasers
- Performed layout design for the packaging, shipping and receiving department.
- Calculated required WIP quantities in-between all processing steps.
Compressed Gas Equipment Manufacturer
Regulator, Valve, CGA Fitting and Manifold Design, Fabricate, Assembly & Test Manufacturer
- Implemented 5 manufacturing cells with components staged at point of use for manual assembly. This reduced inventory levels and increased production efficiency 15%.
Football Helmet Manufacturer & Reconditioner
- Designed complete process layout rearrangement that reduced travel distances 20%
- Designed packaging layout for new helmet packaging.
Corning, Shizuoka, Japan
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Small Batch Chemical Company
– Chemical mixing, blending and packaging company.
- Performed a 3 Phase site expansion feasibility study.
- Created several site and facility layouts for revision and updating.
- Calculated manpower savings from a consolidated barrel filling operation.
- Generated material handling costs for a $30 million, 3 line automatic, 55 gallon filling stations.
- Provided project management meetings, presentations within budget.
Northern Stamping
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