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Design For Lean
Design For Lean
throughput that delivers the said value would be in a facility that is designed with the
throughput in mind.
What is DFL?
Why is it needed?
Where is it applicable?
What is DFL?
Design for Lean (DFL) is an approach for designing any facility that has a product or
a service as an output. The objective is to set and operationalize a minimal waste,
minimal loss process for a product or a service. Through DFL, process excellence is
built-in in the system.
Why is it needed?
A facility with the throughput fitted-in would typically demand high investments in
material handling, require the product to travel long distances in its value stream,
frequently suffer from shortage of space, have unplanned storage points and
unplanned inventory, is likely to have unbalanced capacities which would lead to
bottlenecks and congestion; would have higher supervision requirements and the
operators are likely to cover higher distances for their operation.
Where is it applicable?
DFL can be applied in any context where there is a process delivering a product or a
service. More specifically, this would be ideal in setting up new plants - Greenfield Projects
(Discrete / process manufacturing, Services etc). It is also applicable in setting up new
processes or new product lines or while revamping existing layouts. DFL is also useful
when setting up plants based on product family and PQ Analysis or setting up warehouses,
retail marts, super markets, transport hubs, etc.,
To reinforce, DFL can be applied to any process that has an output catering to a customer
demand. This unit of output can either be a product or a service.
The customer may have information on product demand, in addition to some constraints
like floor space available, assembling/process cost per product/document, available or max
manpower and budgets for setting up of the entire line.
a) Customer demand (Takt Time, Lead Time, etc. for the process
b) Optimized Layout plan based on floor space available for building line
c) Designing of Stations for assembly/processing (# of stations, CT, # of operators,
etc.)
d) Sequencing of processes/activities (Optimal sequence, etc.)
e) Application of Assembly/Processing Principles
f) Ergonomics study for stress-free operations
g) Application of Lean Principles
h) Safety analysis to achieve industry standards
i) Quality Conformance and error proofing
j) Identifications of Machine/Tools/Fixtures (Selection, ease of maintainability and
operability)
k) Logistics for Material (Optimum travel routes, part presentations, bins, frequency,
etc.)
l) Standardization (Video, Pictures, standard work instructions, etc.)
BMGIs DFL team will work with you to design your facility through DFL approach
that will set the platform for process excellence in your organization. To know more,
call us.