Round 4 – Creating a Lean Layout
Now, get some distance to the model and think about an optimized plant layout.
Your Tasks in this Game Round
Do not hesitate to move the stations, Warehouse and Material Floor Markings to optimize the process flow. Think of shorter distances between the stations. Keep logistic aisle for the fork lift driver as required.
Sketch the chosen lean layout on the handout.
Feed material to the stations. Trace all routes that the forklift travels within this assembly sequence.
Assemble 6 pens according to the Customer Request with the updated layout and measure the assembly time with the stopwatch.
Note the time on the Scorecard and compare it with the previous assembly time you achieved.
Try to simulate a U-shape or a straight layout with all stations close to each other.
Feel free to separate the Warehouse from the Shipping Area and bring them close to its operation.