Learning Goal: Design efficient workstation and line layouts to minimise handling and motion waste.

Complete Lesson Content:
Layout affects material flow and operator fatigue. Common layouts: straight line, U‑shaped, and modular cells. U‑shaped lines allow operators to handle multiple stations and reduce material transport distance. Ergonomic workstation design (adjustable chair height, proper lighting, parts within reach) improves productivity and reduces health issues. 5S principles (covered later) apply here.

Definitions:

  • Straight Line Layout – machines arranged in a long row; material enters one end, exits the other.
  • U‑shaped Layout – operators sit inside the U; input and output are close, reducing motion.

Step‑by‑step Explanation:

  1. Assess the garment’s operation sequence.
  2. Choose layout: U‑shaped for small teams, straight line for long lines with many operators.
  3. Place machines in order of operations; ensure space for WIP between stations.
  4. Design workstation: place frequently used tools on dominant side, adjust chair height, use tiltable tables.
  5. Ensure proper lighting (750–1000 lux for sewing).

Best Practices: Involve operators in workstation improvement; they know the pain points.

Common Mistakes: Placing an ironing station far from the sewing line, causing excessive walking and WIP accumulation.

Real Industry Example: A shirt factory converted a straight line to a U‑shaped module; operators could see each other, communication improved, and material handling distance reduced by 40%.

Mini Case Study: A factory had high absenteeism due to back pain; an ergonomic study revealed incorrect chair heights. Providing adjustable chairs and training on posture reduced absenteeism by 15%.

Practical Activity: Sketch a U‑shaped layout for a 5‑operator team assembling a simple top, indicating machine types and material flow.

Assignment: Design an ideal workstation for a sewing operator, describing chair, table height, lighting, and tool placement. Include a diagram.

Lesson Summary: Good layout and workstation design are invisible productivity boosters.

Key Takeaways:

  • U‑shape reduces transport.
  • Ergonomics impact health and output.
  • Operators should help design their space.
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