The document summarizes a case study where an automotive company hired a consulting firm to redesign the layout of their plant. The company wanted to acquire new machinery, which required redesigning a large section of the plant. The consulting firm conducted an analysis of the plant, proposed and evaluated layout solutions, and supervised the implementation of the new layout. The redesigned layout optimized space usage, improved material flow and reduced production stoppages, coming in on schedule and avoiding errors.

1. CaseStudy
Improvement of layout in a company
belonging to the automotive sector
Many of FeedBackGround’s powerful and important
experiences in layout improvement have been acquired in the
automotive sector. Day-to-day activity does not always allow the
spatial needs of each element in the plant to be analyzed in-
depth. Furthermore, the paradigms inherited over the years
hinder the emergence of new ideas. In most cases, internal
personnel are unable to devote attention to this matter or do not
have an overall vision. Below we describe a particular case
successfully solved.
Executive Summary Strategy/Approach
 Our client wished to extend its portfolio of products FeedBackGround’s contribution to this project was as
with the acquisition of new machinery follows:
 This made it necessary to redesign a sufficiently  To conduct a casuistical analysis of the plant in a
week
large section of the plant
 To draw up, compare and discuss layout and
 The client took this as the opportunity to redesign
logistical flow proposals and solutions
the entire layout of the plant in order to optimize
efficiency  To evaluate and select solutions to enable
improved performance to be achieved
 Given the nature of the product, the flow of raw
material and finished product was of prime  To plan introduction of solutions in detail and reach
importance agreement on the plan with all those involved
 The impossibility of expansion on the industrial  To determine the costs and resources associated
estate had restricted plant space to a critical with the plan
extent.
 To supervise assembly of the new machinery and
the redistribution of existing elements
Opportunity Results
 This was the key moment at which to rethink the  Project lasting for 3 months with the participation of
layout of the plant, both for the present and the one part-time consultant and occasional support
future from a project Director
 The training and experience of management  New machinery put in place with optimization of
personnel were optimum for achieving the best available space
results
 Improvement in flow of goods has reduced
 Internal friction and unhelpful company culture made stoppages on the line caused by lack of material
it difficult to achieve the best results in the absence of supply
an important project to justify significant changes in
the company  Redistribution was carried out on schedule and
errors averted, thereby obviating the need to
 It was advisable to study the company to determine
repeat work againThe opportunity was taken to lay
how it was run and decide on the best new layout
the foundations for teamwork among
 Clear possibility of improvement existed (with return management personnel
on investment) in the short-term
Contact name: Màrius Mollà
Position: Partner and Director of Projects
marius.molla@feedbackground.com Customer experience – Sept. 2012
Telephone:+34 619762870 www.feedbackground.com