Lean Design Process

For most industrial engineers, the opportunity to redesign an entire production line comes once or maybe twice in a career. At Leonardo Group Americas, we have designed thousands of lines. The result of our decades of experience is the Mixed Model Line Design Roadmap, a series of documented steps proven to create world-class production lines.

Step 1

Step 1

Create Assessment and Master Plan

  • Complete self-assessment
  • Appoint Lean team leadership
  • Train line design team
  • Review corporate goals and pain points
  • Walk the Gemba
  • Prepare value stream maps
  • Develop future state value stream map
  • Quantify value of opportunities
  • Prepare master plan
Step 2

Step 2

Gather Data

  • Confirm target areas
  • List all products and options
  • Establish volumes and mix
  • Document processes
  • List production resources
  • Create Process Flow Diagram
  • Create Process Flow Matrix
  • Define initial product families
Step 3

Step 3

Develop Standard Work

  • Identify target process
  • Assign DOC team
  • Establish standard work definition form
  • Video process (optional)
  • Document work steps
  • Standardize work steps
  • Establish quantity criteria
  • Record work step times
  • Document supplies and parts
  • Document tools and equipment
  • Conduct staff review
  • Archive standard work definitions in document control
Step 4

Step 4

Line Design Calculations

  • Finalize volumes by product
  • Calculate daily volume by process
  • Establish available work time
  • Calculate Takt time by process
  • Prepare standard time matrix
  • Calculate resources
  • Refine and review resource calculations
Step 5

Step 5

Workstation Definitions

  • Define parallel processes
  • Define sequential processes
  • Define work content by station
  • Detail design of workstations
  • Create graphic work instructions
Step 6

Step 6

Line Balancing Tools

  • Evaluate line balance
  • Eliminate waste
  • Relocate work
  • Add resources
  • Add In-Process Kanbans (IPKs)
  • Add inventory and/or time
  • Introduce sequencing
Step 7

Step 7

Conceptual Layout

  • Gather data and value stream maps
  • Prepare team and workspace
  • Define the high-volume path
  • Lay out feeder processes
  • Lay out resource details
  • Plan materials and IPKs
  • Review conceptual line design
  • Document conceptual design
Step 8

Step 8

Test Design with Simulation

  • Collect simulation data
  • Select simulation software
  • Enter data to test base model
  • Meet target volume and mix
  • Test changes in mix
  • Sanity check
  • Final simulation review
  • Document simulation design
Step 9

Step 9

CAD Layout

  • Review conceptual layout
  • Prepare CAD floorplan
  • Set up CAD system and projector
  • Lay out processes on floorplan
  • Detail the physical layout plan
  • Perform on-site reality check
  • Prepare layout documents
Step 10

Step 10

Deployment Plan

  • Review line and physical layout
  • Plan equipment procurement
  • Plan facilities improvements
  • Set deployment sequencing
  • Build project management spreadsheet
  • Assign dates and responsibilities
  • Approve capital and expense budgets
  • Launch physical layout and move
Step 11

Step 11

Conduct Training

  • Review all work documents
  • Define skills by process and/or station
  • Assess current skill level
  • Conduct Lean overview training
  • Train to the workstation
  • Certify operators
  • Sustain skill levels
Step 12

Step 12

Lean Process Live

  • Verify deployment plan is complete
  • Verify training plan is complete
  • Determine start-up strategy
  • Set and communicate metrics
  • Confirm parts and Kanban chains
  • Communicate and build buy-in
  • Prepare the workspace
  • "Line Live Day"
  • Begin process improvement
  • Celebrate "Lean Line Live"
End Result

End Result

Lean Audit and Certification

  • Evaluate new "Current State"
  • Measure progress toward goals
  • Check the culture
  • Add up the score
  • Certify as Lean
  • Sustain and improve