Investigation of Lean Manufacturing Practices And Plant Layout Design of a Water Bottling Plant From A Sustainability Perspective

Zarrar, Ahmed
Companies around the globe are entering an ever-competitive environment, which harbours new challenges that need to be investigated and dealt with. Manufacturers are finding new ways to maximize operational efficiency, improve productivity, and minimize emissions while reducing direct and indirect costs. To achieve these objectives, lean manufacturing is one of the most renowned frameworks used by the industries' tycoons to stay competitive in the global market. The cardinal aim of this research is to conduct detailed flow and operational analysis, and design a lean sustainable production facility layout for purified bottled water production facility. In this research, manufacturing practices and plant layout of the current production facility are investigated from a sustainability perspective to minimize the core eight lean wastes, which in turn increase the net efficiency and improves overall sustainability of the Company X. Two novel approaches were used to create multiple lean layouts for Company X production facility. The classical Systematic Layout Planning (SLP) was modified to incorporate the lean philosophy. The procedural approach named as ‘Lean Systematic Layout Planning’ (LSLP) was used to develop vi a layout for the new production facility. Later, pair-wise exchange improvement algorithm was applied to further improve the LSLP based layouts. The proposed production facility layout reduced the total distance travelled by 35.02%, reduced the net material handling cost by 37.05%, and decreased the material handling emissions by 36.86% when compared to the current production facility layout. Furthermore, the proposed model significantly improved inventory, streamlined process, minimized congestion, and enhanced space utilization.


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Citation Formats
A. Zarrar, “Investigation of Lean Manufacturing Practices And Plant Layout Design of a Water Bottling Plant From A Sustainability Perspective,” M.S. - Master of Science, Middle East Technical University, 2021.