Application of the lean layout planning system in a leather bags manufacturing plant and proposal of an approach to engage the company’s staff in the research of the layout solution

Since the performance of production systems are often conditioned by the factory layout, it is essential to optimize the placement of machines and facilities inside a plant. This article presents a case study of a “lean” layout planning in a new luxury leather bags manufacturing plant, in which the company decided to move the production. The aim of the new location was to redesign the factory layout in order to reduce efficiency losses. After showing how the lean techniques were implemented in factory layout planning, the article presents a new approach used to engage the company's staff in the achievement of the layout solution. In this perspective, a two-step process was followed: first, the lean strategy was applied to get a prototype layout solution, then the novel involvement approach was used to improve, through an iterative process, the layout result. The article describes the new approach and shows how the layout solution changes with or without the involvement of skilled staff. The use of that approach does not preclude the use of other tools, simulation for instance, to validate the layout. However, this procedure can be helpful in achieving a solution that better satisfies workers, increases morale and productivity, and makes employees accept working changes more quickly.