Lean Manufacturing Plant Layout Design Optimization: Results and Better Material Handling Techniques

Abstract

This study investigates the process of creating better plant layouts through lean manufacturing concepts, which lead to improved material handling processes and operational results. An analytical evaluation through a scoring system determined how existing layouts compared to the proposed layouts by assessing safety standards, along with space efficiency and process flow quality. Through the suggested layout improvements, material movement efficiency increased by 25% while the potential safety hazards rate decreased from 12% to 2-3%. The combination of systematic layout planning with lean tools in the new design leads to a cost-efficient and safer work environment, which demonstrates better performance than the current setup.