Research Article

Lean layout design: a case study applied to the textile industry

Ana Paula Lista; Guilherme Luz Tortorella; Marina Bouzon; Sherif Mostafa; David Romero

Downloads: 0
Views: 8


Paper aims: This research proposes a new facility layout for an Indian textile company based on guidelines for Systematic Layout Planning (SLP) and Lean Manufacturing (LM).

Originality: This paper provides an original industrial case study with valuable insights for practitioners interested in layout redesign. The obtained results encourage assuming its transferability to similar situations than textile industry.

Research method: To showcase the application of LM on plant layout design, an ABC Industries’ facility is selected. Information is collected through multiple site visits and semi-structured interviews with the company’s key staff, as well as examination of relevant company documentations.

Main findings: Some of the expected results include costs reduction handling, organic growth elimination, unnecessary movements reduction and less arrangement adjustments.

Implications for theory and practice: This paper provides an original industrial case study with valuable insights for the adaptation of the SLP model to reformulate plant designs.


Lean manufacturing, Plant layout design, Systematic layout planning


Bai, C., Satir, A., & Sarkis, J. (2019). Investing in lean manufacturing practices: an environmental and operational perspective. International Journal of Production Research, 57(4), 1037-1051.

Brahmadeep, & Thomassey, S. (2014). A simulation-based comparison: manual and automatic distribution setup in a textile yarn rewinding unit of a yarn dyeing factory. Simulation Modelling Practice and Theory, 45, 80-90.

De Carlo, F., Arleo, M. A., Borgia, O., and Tucci, M. (2013). Layout design for a low capacity manufacturing line: a case study. International Journal of Engineering Business Management, 5, 5-35.

Decker Junior, C., Ferreira, J. C. E., Henning, E., & Pereira, C. R. (2019). Assessment of shop floor layouts in the context of process plans with alternatives. Production, 29, 29.

Djassemi, M. (2007). Improving factory layout under a mixed floor and overhead material handling condition. Journal of Manufacturing Technology Management, 18(3), 281-291.

Dongre, A., & Mohite, N. Y. (2015). Significance of selection of material handling system design in industry – A review. International Journal of Engineering Research and General Science, 3(2), 76-79.

Durmusoglu, Z. D. (2018). A TOPSIS-based approach for sustainable layout design: activity relation chart evaluation. Kybernetes, 47(10), 2012-2024.

Flessas, M., Rizzardi, V., Tortorella, G. L., Fettermann, D., & Marodin, G. A. (2015). Layout performance indicators and systematic planning: A case study in a southern Brazilian restaurant. British Food Journal, 117(8), 2098-2111.

Fogliatto, F. S., Tortorella, G. L., Anzanello, M. J., & Tonetto, L. M. (2019). Lean-oriented layout design of a health care facility. Quality Management in Health Care, 28(1), 25-32. PMid:30586119.

Gnanavel, S. S., Balasubramanian, V., & Narendran, T. T. (2015). Suzhal – An alternative layout to improve productivity and worker well-being in labor demanded lean environment. Procedia Manufacturing, 3, 574-580.

Henao, R., Sarache, W., & Gómez, I. (2019). Lean manufacturing and sustainable performance: Trends and future challenges. Journal of Cleaner Production, 208, 99-116.

Hicks, C., McGovern, T., Prior, G., & Smith, I. (2015). Applying lean principles to the design of healthcare facilities. International Journal of Production Economics, 170, 677-686.

Inglay, R. S., & Dhalla, R. S. (2010). Application of systematic layout planning in hypermarkets. In Proceedings of the 2010 International Conference on Industrial Engineering and Operations Management (pp. 9-10). USA: IEOM Society International.

Jones, D., Womack, J., Brunt, D., Lovejoy, M., & Shook, J. (2011). Seeing the whole value stream. Cambridge, USA: Lean Enterprise Institute.

Kim, T., Lim, H., Lee, U. K., Cha, M., Cho, H., & Kang, K. I. (2012). Advanced formwork method integrated with a layout planning model for tall building construction. Canadian Journal of Civil Engineering, 39(11), 1173-1183.

Klausnitzer, A., & Lasch, R. (2019). Optimal facility layout and material handling network design. Computers & Operations Research, 103, 237-251.

Kovács, G. (2020). Combination of Lean value-oriented conception and facility layout design for even more significant efficiency improvement and cost reduction. International Journal of Production Research, 58(10), 1-21.

Lin, Q. L., Liu, H. C., Wang, D. J., & Liu, L. (2015). Integrating systematic layout planning with fuzzy constraint theory to design and optimize the facility layout for operating theatre in hospitals. Journal of Intelligent Manufacturing, 26(1), 87-95.

Liu, J., & Liu, J. (2019). Applying multi-objective ant colony optimization algorithm for solving the unequal area facility layout problems. Applied Soft Computing, 74, 167-189.

Luz, G. P., Tortorella, G. L., Bouzon, M., Garza-Reyes, J., & Gaiardelli, P. (2020). Proposition of a method for stochastic analysis of value streams. Production Planning and Control, 1-17.

Marodin, G. A., Saurin, T. A., Tortorella, G. L., & Denicol, J. (2015). How context factors influence lean production practices in manufacturing cells. International Journal of Advanced Manufacturing Technology, 79(5), 1389-1399.

Matt, D. T. (2014). Adaptation of the value stream mapping approach to the design of lean engineer-to-order production systems. Journal of Manufacturing Technology Management, 25(3), 334-350.

Muther, R. (1973). Systematic layout planning. Kansas City: Management & Industrial Research Publication.

Naqvi, S. A., Fahad, M., Atir, M., Zubair, M., & Shehzad, M. M. (2016). Productivity improvement of a manufacturing facility using systematic layout planning. Cogent Engineering, 3(1), 1207296.

Pattanaik, L. N., & Sharma, B. P. (2009). Implementing lean manufacturing with cellular layout: a case study. International Journal of Advanced Manufacturing Technology, 42(7-8), 772-779.

Rawabdeh, I., & Tahboub, K. (2006). A new heuristic approach for a computer‐aided facility layout. Journal of Manufacturing Technology Management, 17(7), 962-986.

Rother, M., & Shook, J. (2003). Learning to see: value stream mapping to add value and eliminate muda. Cambridge, USA: Lean Enterprise Institute.

Ruiz, S., Simón, A., Sotelo, F., & Raymundo, C. (2019). Optimized plant distribution and 5S model that allows SMEs to increase productivity in textiles. In: Proceedings of the LACCEI International Multi-Conference for Engineering, Education and Technology. Montego Bay, Jamaica.

Santos, L. C., Cláudia Fabiana, G. O. H. R., & Urio, L. C. S. (2014). Planejamento sistemático de layout em pequenas empresas: uma aplicação em uma fábrica de baterias automotivas. Revista Espacios, 35(7), 14.

Santos, Y. M., Torres, O. V. C., Leyva, L. L. L., Granda, I. D. H., Orges, C. A. M., & Saraguro Piarpuezan, R. V. (2019, July 23-26). Improvement plant layout of production line in textile company: a case study. In Proceedings of the International Conference on Industrial Engineering and Operations Management (pp. 741-750). Pilsen, Czech Republic.

Shewale, P. P., Shete, M. S., & Sane, S. M. (2012). Improvement in plant layout using systematic layout planning (SLP) for increased productivity. International Journal of Advanced Engineering Research and Studies, 1(3), 259-261.

Slack, N., Chambers, S., & Johnston, R. (2010). Operations management (6th ed.). Hoboken: Financial Times Prentice Hall.

Tomelin, M., & Colmenero, J. C. (2010). Método para definição de layout em sistemas job-shop baseado em dados históricos. Production, 20(2), 274-289.

Tortorella, G. L., & Fogliatto, F. S. (2008). Planejamento sistemático de layout com apoio de análise de decisão multicritério. Production, 18(3), 609-624.

Tortorella, G. L., Fogliatto, F. S., Anzanello, M., Marodin, G. A., Garcia, M., & Reis Esteves, R. (2017). Making the value flow: application of value stream mapping in a Brazilian public healthcare organisation. Total Quality Management & Business Excellence, 28(13-14), 1544-1558.

Tortorella, G., Silva, G., Campos, L. M. S., Pizzeta, C., Latosinski, A., & Soares, A. (2018). Productivity improvement in solid waste recycling centres through lean implementation aided by multi-criteria decision analysis. Benchmarking, 25(5), 1480-1499.

Watanapa, A., and Wiyaratn, W. (2012). Systematic layout planning to assist plant layout: case study pulley factory. Applied Mechanics and Materials, 110-116, 3952-3956.

Yang, T., Su, C. T., & Hsu, Y. R. (2000). Systematic layout planning: a study on semiconductor wafer fabrication facilities. International Journal of Operations & Production Management, 20(11), 1359-1371.

Zhang, Z., Wang, X., Wang, X., Cui, F., & Cheng, H. (2019). A simulation-based approach for plant layout design and production planning. Journal of Ambient Intelligence and Humanized Computing, 10(3), 1217-1230.

Zhenyuan, J., Xiaohong, L. U., Wei, W., Defeng, J., & Lijun, W. (2011). Design and implementation of lean facility layout system of a production line. International Journal of Industrial Engineering, 18(5), 260-269.

Submitted date:

Accepted date:

619f83c0a953954857736fe2 production Articles
Links & Downloads


Share this page
Page Sections