Designing production space using Lean methodology

Technical Task (TT)

Designing the Production Space According to Lean Methodology (layout, workstations, lighting, flow logic)

1) Project Goal

To design the production space based on the principles of Lean (Flow, 5S, minimization of MUDA, visual management): optimal placement of tables/lines, zones, lighting, and logic of material/people movement, to:

• reduce movement and cycle time;

• eliminate bottlenecks;

• increase productivity and quality;

• make the space scalable for growth.

2) What is Required from the Performer (Scope of Work)

2.1. Survey and Data Collection

• Site visit (or work according to plan/video — if agreed).

• Collection of initial data: area, heights, electricity, ventilation, windows, passages, constraints.

• Description of the process: main stages of production, roles, volumes, takt/target output (to be agreed).

2.2. Lean Analysis

• Building flow logic (Value Stream/Flow diagram at the zone level).

• Movement analysis (Spaghetti diagram) for the current/base variant (if available).

• Identification of MUDA in the space: unnecessary movements, waiting, excess inventory, cross flows, etc.

2.3. Planning Design
Prepare 2–3 layout options with justification:

• placement of lines/tables by operations;

• zones: storage/assembly, production, QC, packaging/shipping, repair/rework, office/engineering (if necessary);

• places for carts, racks, WIP buffers (with limits);

• movement logic: materials → production → control → packaging → shipping (without “counter” flows);

• standards for passages, safety, evacuation (without fanaticism, but with adequate norms).

2.4. Placement of Workstations and Tables

• Typical “modules” of the workstation (1 station / 2 stations / line), recommended dimensions.

• Ergonomics principles: table height, tool placement, “reach zone”.

• Visual management: labeling, shadow boards, tool places, signs/statuses.

2.5. Lighting

• Calculation/recommendations for lighting for different zones (assembly, soldering, QC, storage).

• Lighting placement scheme (plan with attachment), recommendations for light type/CRI, local lighting at stations, requirements for flicker-free (important for soldering/QC).

• Minimization of shadows on work surfaces.

2.6. Communications and Engineering (at the TT/preparation level)

• Final TT/recommendations for the electrician: 220V power points, sockets at stations, general lines, emergency power (if necessary).

• Low voltage: network/internet, points for label printers/scanners.

• (Optionally) recommendations for ventilation/extraction for soldering.

3) Input Data from the Client (we will provide)

• Room plan (BTI/AutoCAD/PDF) or measurements.

• Photos/videos of the room.

• List of operations/areas and approximate number of people for each.

• Target output/shifts and work mode.

• List of main equipment/tables/racks (what is available and what is planned to be purchased).

• Constraints: “this cannot be moved”, “this must be here”, etc.

4) Requirements for the Result (deliverables)

The performer must provide:

1. Planning (layout) 2–3 options + selected final.

2. Final placement plan (PDF + output: DWG/SketchUp/Visio/Figma — whatever the performer has).

3. Flow diagram: materials/people/waste/final products.

4. Plan for the placement of tables/stations with dimensions.

5. Plan for lighting (placement + specification/recommendations).

6. Short report: key decisions, “why this way”, risks, what needs to be purchased (racks/carts/labeling).

7. (Optionally) implementation plan: what we do in the first 2 weeks / 1 month.

5) Quality Criteria (how we will accept the work)

• Flow without crossings, logical zones, clear material path.

• Minimization of unnecessary movements (comparison “before/after” at least qualitatively or in meters).

• Designated places for WIP with limits.

• Workstations are ergonomic and repeatable (can be scaled).

• Lighting corresponds to the type of work (soldering/QC — special attention).

• The plan is realistic for the installation of electricity/lighting.

6) Interaction Format

• 1–2 working sessions for data collection.

• Intermediate defense: presentation of layout options.

• Final submission with revisions (1–2 iterations included).

7) Requirements for the Performer

• Experience in designing production spaces / Lean-layout / industrial design.

• Portfolio with similar cases (preferred).

• Ability to work with room plans and prepare drawings/schemes.

8) What to Include in the Feedback/Proposal (to help us choose quickly)

• Examples of work (links/files).

• Approximate approach/stages and timelines.

• Cost: fixed or hourly + what is included.

• Is a site visit possible (Kyiv/region — we will clarify in correspondence).