Develop Line Layout

Purpose: The Line Layout is to graphically represent the facility, machines and material flow. This document will be used to move equipment, identify IPKs (In Process Kanbans), storage locations and line-side material locations. People who will be working on the flow line will be able to view relationships between equipment and operations to identify details omitted during operational definition and line layout.

Step 1: Obtain the block layout, resource calculations and operational definitions.

Step 2: Obtain foot print requirements for equipment, materials and personnel.

Step 3: Obtain a facility layout that contains the columns, drains and any other pertinent services. Include any equipment that has been designated as a monument, e. g., a heat treat furnace.

Step 4: Based on the Block Layout place the required equipment and workbenches for the main line. Start the placement at the end of the line, the beginning of the line, or at the point where a monument resides. Allow enough room for the operators to work on the product comfortably, with the material to be presented close at hand. Include the IPKs based on the size of the product at that point in the line. If the product is mature and rapid growth is not expected, work towards a dense layout. At constrained machines, consider allowing additional room so machine tools can be added at a later date.
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Updated: 12Jun2005

Step 5: Place the feeders at the points where they need to attach to the main line. Place the In-Process Kanbans (IPKs) on the feeder and at the point of consumption on the main line.

Step 7: Determine where Raw-in-Processes (RIPs) should be located and define an approximation of the area/s required on the layout.

Step 8: Review the layout for product flow, material space required, material movement and signaling via IPKs.

Step 9: Document this revision of the layout and repeat all the steps. This is an interactive process that may take 4 or 5 revisions before all parties agree that the result is the best alternative.

Step 10: When an agreement is made that the best alternative has been reached, lay in all the required electrical, air, communications, water and any other required services.

Updated: 12Jun2005