ABSTRACT
The first S in the BASICS model stands for Suggest Solutions, and this chapter introduces the balance of the tools and how to proceed once the analysis is completed. There are many pieces to a Lean implementation and they are all interconnected. Lean consultants use the process block diagram to help them determine the layout and workstation design for the line. When implementing Lean lines, consultants want to create flexible layouts, with everything possible on wheels, as customers have changing needs and demands. Lean layouts should promote flexible workspace design. Layout redesigns should result in a decrease in overall space and travel distance needed to perform a task and eliminate/minimize fractional labor. The most important thing to avoid in any layout is isolated islands. The operator moves from machine to machine and generally has a bunch of idle time. Each machine is producing different batches of parts that may or may not be in router sequence.
