Lean Facility Layout Solutions For Factories And Warehouses
Moving your operation or changing your layout is a complex exercise bringing with it a high risk of disruption to your business and customers.
Getting your layout wrong can lock excess cost and inefficiency into your business for decades. In our experience a well planned and executed layout change can yield space reductions of over 50%, productivity improvements of up to 40% and lead to reductions in inventory and production lead time exceeding 50%.
Getting your facility layout right the first time will save you a lot of time, money and future pain.
Our Facility Layout Development Process will make sure every square inch of your new facility counts. We will also help you use your facility to take your business to the next level with improved efficiency and safety.
Reorganising Your Facility for Maximum Efficiency
TXM has assisted well over 100 companies to design layouts for factories, warehouses and workshops. The proven TXM Lean Facility Layout Development Process applies Lean Tools in a structured way to enable you to completely re-think the layout of your next facility.
The TXM Facility Layout Development Process is designed to bring together all the relevant parties to make sure we all understand the full picture before committing to moving machinery and workstations.
Why Choose TXM?
The TXM Facility Layout Development Process will deliver:
- Reductions in Material Handling Distance and Time;
- Save Floor Space;
- More Revenue for a Given Amount of Space
- Increased Productivity and Reduced Waste
- Improved Safety
- Lower Building & Capital Costs
- Lower Ongoing Operating Costs
Frequently Asked Questions About Lean Facility Layout
What Is Lean Facility Layout And How Does TXM Lean Solutions Implement It?
A Lean Facility Layout is a layout design for a factory, warehouse, laboratory or workshop that is based on Lean thinking. A Lean Facility Layout is designed from the start to optimise workflow and to minimise all forms of waste.
At TXM Lean Solutions we have created hundreds of Lean Facility Layouts for a huge range of processes. We start with the most important question – what is the purpose of facility and what value will it create? From this, our step-by-step process will redesign your process and deliver a layout that produces higher productivity, higher capacity, better safety and makes the best possible use of available space.
How Can We Help Reduce Material Handling Costs Through Lean Layout Design?
By designing efficient material flows that operate with reduced inventory and bring materials closer to where they are needed, and by eliminating unnecessary walking for staff, TXM can deliver dramatic cost reductions, often exceeding 20% of overall labour cost.
Few people realise that a larger facility is inherently less efficient. This is because a larger facility inevitably means greater distance for staff to travel and for materials to be transported.
What Are The Key Benefits Of Implementing A Lean Facility Layout With TXM?
With TXM you are benefiting from our massive knowledge base developed across hundreds of similar facility layouts and our proven process.
By following our process you will make improvements you never imagined possible and maximise the return on your investment in a new facility.
Importantly we work with a cross functional team of your people to develop the layout. So at every point, your team are in control of the key decisions and have ownership for the ultimate result.
How Does TXM’s Lean Layout Approach Improve Workflow Efficiency And Productivity?
The TXM Facility Layout Development Process delivers dramatic gains in efficiency and productivity. We coach your team to redesign your process from the ground up.
We typically achieve productivity gains exceeding 20% and over 30% more output from the same space. In fact on several projects we have more than halved the manufacturing footprint and delivered lead time and work in progress savings of more than 80%.
What Industries Does TXM Lean Solutions Specialise In For Facility Layout Optimisation?
TXM specialise in layout design for factories and warehouses.
However our facility layout development process has been shown to work equally effectively in:
- Laboratories
- Maintenance, Repair and Overhaul (MRO)
- Outdoor areas such storage yards
How Long Does A Typical Lean Facility Layout Project Take With TXM Lean Solutions?
We can complete a Facility Layout design in as little as one week.
However, to get the best result we recommend allowing time to collect process data and to allow time for teams to review and reflect between Facility Layout Development process workshops.
Therefore, most of our facility layout development process projects are completed over a period of two to three months, with our consultant on site every one to two weeks.
What Is The ROI Timeline For Our Lean Facility Layout Improvements?
On one project we saved the client $US5,000,000 in building costs alone for an investment of under $US50,000, in other works a return of 100:1 and that does not even include the ongoing operational cost savings.
Building or renting new facilities is extremely expensive. The land and building costs for a basic 1000m2 easily exceeds $US1m. So the question is not whether you can afford to use the TXM Lean Facility Layout Development Process, but can you afford not to?
What Tools And Methodologies Do We Use For Lean Layout Analysis?
The TXM Facility Layout Development Process is based on proven Lean techniques adapted from the Toyota Production System.
At the core of Facility Layout Development Process is TXM’s unique approach to Value Stream Mapping of complex, high mix, low volume and bespoke processes, the Manufacturing Agility Process®. By developing a future state map with the Manufacturing Agility Process® first, we ensure that your process is perfectly aligned to the future layout of your business.
We complement this with Practical 5S tools such as
- Spaghetti flow mapping
- Targeted “set in order”
- A3 one page plans