PROPOSAL OF MASTER’S THESIS

Optimization of shop floor layout

using lean concepts
supervisors
Professor. Ahmed El-Assal
Assistant Professor . Magdy Helal

By
Mahmoud Asfour

Benha High Institute Of Technology

MSc programmes in engineering

Department of mechanical engineering
1- Introduction

Heightening challenges in today’s global competition have prompted many

manufacturing firms to adopt new manufacturing management strategies in
order to enhance the firms’ efficiency and competitiveness. Lean manufacturing
is a manufacturing strategy that aimed to achieve smooth production flow by
eliminating waste and by increasing the activities value.

Design of plant layout is to ensure a smooth flow of work, material, and

information through the system [14]
History of lean manufacturing

Eli Whitney concept of interchangeable parts(1799)

Frederick W. Taylor SOP and time study

Frank Gilbreth Process charts and motion study

Henry ford Assembly line and flow lines(1910)

Taichii ohno TPS,JIT and stockless production(1950)

Lean manufacturing (1990)

Lean concepts and principles.
Lean manufacturing [5]
Lean is basically all about getting the right things, to the right place, at the
right time, in the right quantity while minimizing waste and being flexible and
open to change.
The five lean principles

1-Value
Value is any activity in the process that is essential to deliver the service or product to the
customer.
2-Flow
In lean manufacturing the smoothness of material, information and process flow have a great
value to add value for the processes.
3-PULL
Pull production in which the flow on the factory floor is driven by demand from downstream
pulling upstream as opposed to traditional batch production.
4-Responsiveness to change
Central to the lean principle of responsiveness is delivering quality products or services as
promised, when required, and at the agreed-on price.
5-Endless pursuit of perfection
Continuous improvement is a core for implementing lean manufacturing.
Principles of plant layout [4]

1- Principle of integration: A good layout is one that integrates men,

materials, machines and supporting services and others in order to get the
optimum utilization of resources and maximum effectiveness.

2- Principle of minimum distance.

3- Principle of cubic space utilization.

4- Principle of flow.

5- Principle of maximum flexibility: The good layout is one that can be

altered without much cost and time.

6- Principle of safety, security and satisfaction.

7-Principle of minimum handling.

Layout types

1- Product layout.

2- Process layout.

3- cellular layout.

4- Fixed position layout.

Considerations of layout in lean.
1-Shorter lead time to obtain the product.
Lead time is the period between a customer's order and delivery of the
final product.

2-Machines should be arranged as close as possible to one other i.e. close

coupling.

3-All material movement distance required in operations, should be

minimized as much as is feasible.

4-Reduce the number of touches for the product.

5-Flexible to accommodate demand changes.

6-Achieve Pull production (continuous flow).

7-Utilization for all resources that used.

8-Be organized and visualized.

9-Reduce the Changeover time.

Tools used in optimization of shop floor layout with lean concepts.
Value stream mapping.
Kanban
Simulation
Standard operating procedures
Celluluar manufacturing
11- References
[1] For effective facilities planning: layout optimization then simulation, or vice versa?
(Paper).
[2] Technical note “MC GRAW HILL” (Book).
[3] Lean applications in shop floor layout design (Master thesis).
[4] Production management course “new Delhi institute”(Lectures).
[5] Kaizen by john shook (book).
[6] The illustrated lean (book).
[7] Tools and techniques for enabling sustainability through lean initiatives (PAPER).
[8] Current State Value Stream Mapping gemba academy (lecture).
[9] Redesigning an assembly line through lean manufacturing tools (PAPER).
[10] SIMULATION-BASED LAYOUT PLANNING OF A PRODUCTION PLANT (PAPER).
[11] IMPLEMENTING LEAN MANUFACTURING WITH CELLULAR LAYOUT (PAPER).
[12] Lean philosophy: implementation in a forging company (PAPER).
[13] Value stream mapping: literature review and implications for Indian industry
(PAPER).
[14] LAYOUT PLANNING WITH ISLES: A GENETIC APPROACH (PAPER).
[15] WHY LEAN NEEDS SIMULATION (PAPER).