Manufacturing Line Footprint Reduction Through Kaizen-Driven Layout Optimization
Author(s): Sai Prasad Ravulapally
Publication #: 2603033
Date of Publication: 26.03.2026
Country: United States
Pages: 1-5
Published In: Volume 12 Issue 2 March-2026
DOI: https://doi.org/10.62970/IJIRCT.v12.i2.2603033
Abstract
Manufacturing organizations are increasingly experiencing space challenges while also seeking to enhance efficiency and operational flexibility. Traditional responses, like expanding facilities, require a lot of money and cause problems with operations. Lean manufacturing principles, especially Kaizen-driven continuous improvement, offer a different way to get through by getting rid of waste and improving the layout. This study provides an industrial case analysis of the reduction of manufacturing footprint in a chainsaw assembly line within a facility that makes outdoor power tools. The goal of the project was to cut down on the amount of space used on the production floor from 8,000 square feet to 5,000 square feet while maintaining or improving the performance of the production floor. By using Value Stream Mapping, line balancing, 5S implementation, visual management, and layout redesign as part of a structured continuous improvement effort, the production footprint was cut down to 4,600 square feet, or 42.5%. At the same time, the cycle time went from 24 seconds to 20 seconds per unit, the production capacity went up by 20%, the work-in-process inventory was cut down to zero, and the distance operators had to travel went down by 72%. A financial analysis shows that the company will save about $510,000 by not expanding its facilities. The results show that changing the layout using Kaizen can improve efficiency, productivity, and operational sustainability simultaneously, without adding more workers. This research provides practical and scholarly insights into the integration of Lean manufacturing with industrial engineering layout optimization strategies.
Keywords: Kaizen, Lean Manufacturing, Footprint Reduction, Layout Optimization, One-Piece Flow, Continuous Improvement, 5S, Efficiency.
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