Process improvement and layout optimization in a forging company

Andrea Bogert, William Edwards, Farzad Jalali, Faisal Aqlan

Research output: Contribution to journalConference articlepeer-review

1 Scopus citations


Optimization of production layout in manufacturing can be achieved through process improvement methods. Lean manufacturing is a common process improvement method that has been implemented by many originations and proven successful outcomes. Lean manufacturing is used to identify, analyze, and optimize internal material flow. In this paper, we discuss the implementation of Lean process improvement to optimize production flow in forging industry. The study is conducted in a custom steel forge shop that utilizes 2,000 ton open forge dies, 11 heat treat furnaces, and 5 quenching stations to manufacture large metal parts for oil and gas, military, mining, automotive, and aerospace industries. Currently, the shop is facing issues in the efficiency of the product flow and plant layout. Three production areas of interest are considered while re-evaluating the plant layout. Proposed changes are analyzed based on distance and proximity importance. The layout alternatives are compared based on Net Present Value (NPV) and payback period. The final results show the proposed changes will reduce product travel time as well as relieve bottlenecks in the shipping bay.

Original languageEnglish (US)
Pages (from-to)1162-1170
Number of pages9
JournalProceedings of the International Conference on Industrial Engineering and Operations Management
Issue numberSEP
StatePublished - 2018
Event3rd North American IEOM Conference. IEOM 2018 -
Duration: Sep 27 2018Sep 29 2018

All Science Journal Classification (ASJC) codes

  • Strategy and Management
  • Management Science and Operations Research
  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering


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