Strategic facility & space planning utilising Design for Lean Six Sigma

Figures & data

Figure 1. DFLSS – the DMADV methodology.

Figure 2. SIPOC diagram.

A square listing the team members.

Figure 3. Stakeholder map.

A list of the people involved.

Figure 4. Stakeholder commitment matrix, screenshot of stakeholder spreadsheet.

Table 1. Final project definition.

Problem	The manufacturing organisation was on track to go negative on space within 2 years. No process in place to provide line of sight to the required free space to satisfy the site’s space requirements
Objective	Create a process to strategically plan space moves for the benefit of the manufacturing site using the DMADV methodology.
Scope	In Scope: Production Rooms(P.R.‘s), Labs, Material In/Out, R&D, NPD, Equipment Engineering; Out of Scope: Facilities, Support Staff Offices, I.T., Canteen, Car Park, Finances

Table 2. A 24-month space needs by production area.

Product room	Reason	Space (square foot)	% allocation
Sterilisation & Pack	Expansion of Sterilisation area Phase 1 & 2	31,000	37%
Assembly Product D	Expansion of Products D1 & D3	22,500	27%
Assembly Product A	Expansion of Products A1, A2 & A3	12,500	15%
Assembly Product G	Expansion of Product G1	5,500	7%
Assembly Product B	Expansion of Product B1	5,000	6%
Assembly Product F	Expansion of Product F1 & F2	4,500	5%
Assembly Product E	Goods Storage	1,200	1%
Assembly Product C	Expansion of Products C1 & C2	1,000	1%

Figure 5. Space option 2.

Figure 6. Space option 3.

Figure 7. Space option 4.

Table 3. Space options decision matrix.

	Option 1	Option 2	Option 3	Option 4
Set Up Costs	1	1	1	1
Timelines	3	4	3	3
Operational Costs	3	3	2	1
Ease of Expansion	4	5	3	2
Complexity	3	5	4	3
Total	14	18	13	10

Figure 8. Space option 4.

Figure 9. Affinity diagram (note: SCIA = site change).

Figure 10. Space request process.

Figure 11. Space request process.

Figure 12. Strategic facility planning process roadmap.

The steps for the process.

Figure 13. Strategic facility planning process Roadmap.

Table 4. Breakdown of cost savings.

Before project	After project
1) A requirement of 22,000 sq. foot in new facility space was needed. This was a cost of:22,000 sq. ft X $1,000/Sq. foot = $22 Million	1) No new facility space or zero sq. foot was required. A cost avoidance of $22 million
2) Zero square foot space available	3) 16,000 sq ft of space freed up 9,000 sq ft production space at a cost of 1,000 sq./ft 7,000 sq./ft non-production space at a cost of $600 per sq. ft Total Savings of $13,2000,000
After Project Total Savings = $22 million + $13.2 million = $35.2 Million.