Among the alternative solutions, the most impressive
layout was chosen. The selection technique was the factor
analysis method, which identifies the principal desirable
features (factors) for the new layout. The main factors
considered were: worker flow; process flow; flow
visualization; possible expansion; interaction among
departments; grouping of equipment; flexibility. Each
factor has a weight representing its importance. A score
was assigned to all the layouts identified for each factor.
Next, it was multiplied for the weight of the respective
factors. Finally, each solution received its total score: the
layout with the best total value was the preferred layout.
Figure 6 shows the selected empirical layout.
This result combines product and process layout features.
The workstations, in fact, have a U‐shaped configuration
that follows the sequence of the manufacturing process
activities. However, machines with similar features are in
the same zone. The new layout partially follows the main
workstations’ unification requirements, according to the
reasons presented in section 3: steeping and drying are
nearby, and stiffening and finishing are neighbours in the
same area.
The empirical layout also facilitates a reduction of the
distance between the final phases (stiffening and
finishing) and the other workstations. At the same time,
the tool arrangement was reorganized in a unique area.
This first new layout thus seems to provide important
improvements to the production system.