Japanese Approaches and Trends in Manufacturing Layout
The business philosophy, objectives, and manufacturing methods of Japanese are somewhat different from those of US firms. These differences are reflected in their facility layout. Since space is at a premium in Japan, the Japanese make the most use of what little space is available. Compared to US manufacturing facilities, Japanese factories are quite compact - almost one-third of their US counterparts. These compact layouts, with smaller pieces of equipment closely placed together, aisles squeezed down, and work centers closely placed together, help them save space. They also use areas and train workers for more than one task.
Due to the compactness of the layout, the materials travel shorter distances and products go through the factory faster, resulting in high production rates, quick processing of customer orders, and reduction in materials handling and inventory costs. It also enables the factories to be more flexible to changes in customer orders, production schedules and production rates. Communication and morale within a group also improve as the workers are stationed close to each other.
In general, US manufacturing layouts are designed for high worker and machine utilization, whereas Japanese layouts are designed for flexibility and adaptability to different product models or to different production rates.
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