Lean layout design: a case study applied to the textile industry

Abstract

Paper aims  This research proposes a new facility layout for an Indian textile company based on guidelines for Systematic Layout Planning (SLP) and Lean Manufacturing (LM).

Originality  This paper provides an original industrial case study with valuable insights for practitioners interested in layout redesign. The obtained results encourage assuming its transferability to similar situations than textile industry.

Research method  To showcase the application of LM on plant layout design, an ABC Industries’ facility is selected. Information is collected through multiple site visits and semi-structured interviews with the company’s key staff, as well as examination of relevant company documentations.

Main findings  Some of the expected results include costs reduction handling, organic growth elimination, unnecessary movements reduction and less arrangement adjustments.

Implications for theory and practice  This paper provides an original industrial case study with valuable insights for the adaptation of the SLP model to reformulate plant designs.

Keywords:  Lean manufacturing; Plant layout design; Systematic layout planning