1Project overview
A cellular layout and ten-year capacity plan for an 80,000 ft² metal fabrication plant with 16 departments.
2Objective
Design a layout for an 80,000 ft² metal fabrication facility that can support ten years of growth.
3My role
- Led a cellular layout design using Systematic Layout Planning.
- Developed from-to and activity relationship charts for 16 departments.
- Forecast machine requirements under 15–30% annual growth scenarios.
- Recommended a phased hybrid expansion plan.
- Used NPV and payback analysis to recommend outsourcing welding rather than keeping it in-house.
4Engineering approach
Flow analysis
From-to charts quantified material movement between all 16 departments.
Relationship ratings
Activity relationship charts captured which departments need to be close and which should be apart.
Systematic Layout Planning
Used both to compare layout alternatives and select a cellular design.
Capacity forecast
Projected machine requirements over ten years at 15–30% annual growth to plan phased expansion.
Make vs. buy
NPV and payback analysis on welding, which pointed to outsourcing.
5Analysis and visuals
Image to add: Capacity-planning chart
Machine requirements by year under the 15–30% growth scenarios.
6Results and impact
- ~20%lower material-flow cost than the alternative layout (modeled)
- 10 yrsof growth planned for
The selected cellular layout reduces material-flow cost by about 20% compared with the alternative layout, with a phased plan for growth.