Better Facility Design Using DMAIC
The greatest opportunity to eliminate and/or reduce waste in a very production facility is that the upfront design and planning of the ability. From a construction cost standpoint, it's about as inexpensive to construct a well-planned facility on implement a poorly planned one. Agreement made during the factory planning and style stage have a impressive effect on operational adaptability of the factory. By utilizing the DMAIC (Define, Measure, Analyze, Implement, Control) approach to facilities planning and style, a scientific approach will be wont to produce and optimize facility layout supported Lean Manufacturing principles.
The process will be implemented as follows:
Define – We must first define the products to be manufactured and therefore the manufacturing process(es), as well as, related activities required to supply the merchandise. you'll also must define the amount of product(s) to be manufactured, routing process, supporting services required and timing.
Measure – within the measure phase we must determine the interconnection among all activities and regulate the space requirements for those activities. Creating an Activity Relationship Chart and a cloth Flow Map can prove very helpful at this stage of the method.
Analyze – within the analyze phase block layout alternatives should be developed, as well as, process flow alternatives. We must also create material handling and storage opportunity. Utilizing this information we are able to then generate opportunity facilities plans and evaluate the alternatives. The evaluation process should include listing the positive and negative aspects of every alternative, together with ranking the performance of every alternative against established criterion. Evaluation criteria should include initial investment required, annual operating costs, flexibility or easy changing or rearranging the installed system, easy future expansion, space utilization, availability of apparatus needed and supporting services required.
Implement – While implementing the facilities plan it's important for the facilities planner to get buy-in to the plan from both upper management and workplace employees. After deciding what layout alternative most closely fits evaluation criteria, an in depth layout should be developed. The detailed layout should include location of apparatus, cargo hold for staple and WIP, shipping and receiving area, office locations, Q.C. area, restroom location, waste location area(s), electrical requirements, mechanical requirements and lighting requirements. At now the layout design should be finalize utilizing the services of a licensed architect. Upon conclusion of the architectural layout for the ability, the planning package should move out for bid and therefore the implementation process should start after securing contractor services.
Control – Once the new facilities layout has been implemented, a post-installation audit should be performed to verify that the system is working definitely. If not functioning obviously, determine the causes and rectify. so as to keep up continued facility achievement, custom review of system operation should be appliance.
Utilizing this DMAIC method to the event of your new facility will help ensure production escalation and functionality of your facility for years to come back.