In a reality of global competition, companies have to minimize production costs and increase productivity in order to boost com-petitiveness. Facility layout design is one of the most important and frequently used efficiency improvement methods for reducing operational costs in a significant manner. Facility layout design deals with optimum location of facilities (workstation, machine, etc.) on the shop floor and optimum material flow between these objects. In this article, the objectives and procedure of layout design along with the calculation method for layout optimization are all introduced. The study is practice-oriented because the described case study shows how the layout of an assembly plant can be modified to form an ideal re-layout. The research is novel and innovative because the facility layout design and 4 lean methods (takt-time design, line balance, cellular design and one-piece flow) are all combined in order to improve efficiency more significantly, reduce costs and improve more key performance indicators. From the case study it can be concluded that the layout redesign and lean methods resulted in significant reduction of the following seven indicators: amount of total workflow, material handling cost, total travel distance of goods, space used for assembly, number of workers, labor cost of workers and the number of Kanban stops.

Production companies face the challenge of choosing a suitable process optimization method

from a variety of methods, even though their effect on operational processes is uncertain.

This study shows, using a statistical hypothesis test, the impact of the methods Kanban

and Standard Worksheet on an autonomous team in comparison to a team that applies

these methods. For this purpose, 44 companies – of different size and operating in various

industries – across Germany completed a business game and generated data regarding the

KPIs adherence to delivery date, number of reworks and inventory costs. Based on these

data, the team’s performance could be ascertained and compared with each other.