Figure 10 shows the value stream map of the “as is” state,
from which the future and desired layout was obtained.
The future value stream map is shown in Figure 11. It is
possible to note that the main changes concern the reduction
of waiting times between the final operations and the
reduction of the processing time for the raw material. In the
desired configuration, there is also a new storage area for
semi‐finished products between the two final workstations.
The layout obtained through this lean approach is shown
in figure 12. As is clearly visible, this new layout offers
many benefits, since it derives from an overall redesign of
the felt hat manufacturing process. One of the most
representative elements is the presence of cells: the three
operations of steeping, drying and dying are grouped
into a cell and, therefore, the operator of these activities
can work in a smaller, more ergonomic area than before.
This causes a significant reduction of the transportation of
waste, which is a no‐value added time. Furthermore, this
new layout enables for easier blocking and pumicing,
since they are grouped and organized into two parallel
lines. For this layout, and similar to the previous results,
the workstations are organized sequentially according to
the manufacturing process flow. The advantages of the
previous layouts are proved here again.