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Kaizen - Layout

This document compares three workshop layout options and identifies their pros and cons. Option 1 separates manufacturing from other business, consolidates the machine shop, implements cell-based layout, and reduces bottlenecks. However, it requires capital expenditures and could be disruptive. Option 2 is similar but moves test cells, though it increases material transfer distances. Option 3 creates space by moving paint booths outside but increases travel distances and could have capacity and work environment issues.

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Bradley Nelson
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153 views4 pages

Kaizen - Layout

This document compares three workshop layout options and identifies their pros and cons. Option 1 separates manufacturing from other business, consolidates the machine shop, implements cell-based layout, and reduces bottlenecks. However, it requires capital expenditures and could be disruptive. Option 2 is similar but moves test cells, though it increases material transfer distances. Option 3 creates space by moving paint booths outside but increases travel distances and could have capacity and work environment issues.

Uploaded by

Bradley Nelson
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Kaizen Objectives

• Identifying the Pro’s and Con’s of the different workshop layouts .

Current Pain Points :


Workshop Layout – Option 1
• Pro’s
• Separation of manufacturing business from the traditional business.

• Machine shop consolidated in one bay.

• Cell based manufacturing layout for SPM products, wellhead and valves.

• Reduced movement of material between the bays.

• Improved flow.

• Bottlenecks in test pit reduced.

• Bottlenecks in paint booth reduced.

• Secured storage location (central store ) and more racks added.

• Store moved for easy access for supplier.

• Added 3 new machines, still created additional space (180 + 100 Sqm.)

• Added 3 dedicated test Areas.

• Added 2 dedicated paint booths.

• Added dedicated furnace for valve and well head.

• Con’s
▪ Location of test cell (wellheads) close to the main walk way.

▪ CAPEX approval required for 2 paint booths and 3 test cells.

▪ Expected disruption due to machine movement.

▪ Additional power required.

▪ Approval delays.

▪ Travel distance is more for wellheads and small manifolds.


Workshop Layout – Option 2
• Pro’s
• Same as option 1.

• Location of test cells moved to the end (side of the building).

• Machine flexibility for VTL’s (Nearer to other bigger machines).

• Con’s
▪ CAPEX approvals.

▪ Expected disruption due to machine movement.

▪ Material transfer distance increased ( Both finish machined / WIP) by 200 meters.

▪ Travel Distance for wellhead components increased (Painting) by 120 meters.


Workshop Layout – Option 3
• Pro’s
• Same as option 1.

• Created more space inside by moving paint booth outside.

• Reducing paint booth CAPEX cost.

• Con’s
▪ Shipping of finished goods travel distance is more.

▪ Panting booth outside adds material travel distance to finished goods area ( Min 50 meter for SPM products and API valves).

▪ Shared paint booth could be a capacity constraint.

▪ Additional 180 meters as compared to option 1.

▪ Work environment due to working outside (Paint operations).

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