Tool 72: Facility Layout Diagram

AKA

N/A

Classification

Changing/Implementing (CI)

Tool description

A facility layout diagram displays floor layouts, manufacturing or service process flows, employee movement, possible bottlenecks, excessive cycle time, and other possible inefficiencies in the present layout. This tool prepares a layout of equipment, work areas, and storage areas useful in work flow analysis (WFA) and improvement efforts.

Typical application

• To create a floor plan of the facility for tracing employee movement.

• To identify possible co-location of activities and shorter distances of required movement.

• To map process flows and loopbacks.

Problem-solving phase

→	Select and define problem or opportunity
→	Identify and analyze causes or potential change
→	Develop and plan possible solutions or change
	Implement and evaluate solution or change
	Measure and report solution or change results
	Recognize and reward team efforts

Typically used by

	Research/statistics
	Creativity/innovation
2	Engineering
	Project management
3	Manufacturing
	Marketing/sales
4	Administration/documentation
	Servicing/support
	Customer/quality metrics
1	Change management

links to other tools

before

• Process flowchart

• Cycle time flowchart

• Opportunity analysis

• Mental imaging

• Interview technique

after

• Work flow analysis (WFA)

• Activity analysis

• Variance analysis

• Potential Problem Analysis

• What-if analysis

Notes and key points

For easy reference to any work area, use grid labeling of facility layout. Example:

Step-by-step procedure

• STEP 1 First, identify and observe the facility or work area for the normal work flow, equipment location, and the number of employees normally assigned to workstations. See example Reproduction Facility Layout.

• STEP 2 Using drafting paper, prepare a facility layout diagram showing all major items or equipment, furniture, and other objects or areas of interest.

• STEP 3 Name all drawn items, complete grid reference labeling, and identify the number of people working at certain locations.

• STEP 4 Finally, check for accuracy and date the diagram.

Example of tool application