The physical layout of a plant impacts work flow, production lead times, cycle times, material requirements, and quantity of work to be performed at any given location. Simply put, production layouts matter!
The discipline of plant design includes the use of multiple layouts to accommodate the most efficient and effective flow of resources (labor, material, equipment, etc.). Here are an important few:
A work cell is an arrangement of multiple sequential operations, manual and automated, that produces an output (throughput) to a required cycle time. The work cell may be an input to another production operation or produce a finished good.
A work cell may use a combination of production layouts (see above) that optimize product flow and interactions of people with each other, materials, tooling, and equipment—minimizing WIP, wait times, idle resources, and overall lead times. Work cell designs are often used to achieve one-piece flow (see Chapter 16) objectives.
Work cell designs should achieve these minimum objectives:
Consider the use of the Process Capacity Table, Standard Operations Combination Chart, and Standard Workflow Diagram (Chapter 10) when developing work cell designs.
Industry practices reflect the typical work cell layouts below that best fit design considerations cited previously. It is common for multiple work cells and work cell designs to be linked together:
In all cases, single to multiple operator work cells, the goal is to achieve a balanced line, where one worker is not waiting on the efforts of others. Each cell design requires unique analysis to determine which stations are staffed by what operator. Following are three labor examples of a U-shape work cell design.
Achieving maximum benefit from a work cell will often require a multifunctional worker, meaning an employee trained to handle several different machines and operations. This may require a complete job redesign per contractual or employment expectations.