Is a U-shape line layout always best?

I once had a manager who insisted that all our production lines must be based on a U-shape layout. He never really gave any reason for it apart from saying “it is the lean way of designing layouts”. While he was right in that regard, there are production lines that just won’t work if designed as U-shaped cells. For example, the nature of a process may compel you to have a certain layout shape or your production line may not even be long enough to form a U.

Let’s look at some of the reasons you might want to adopt a U-shaped layout:

If you have a multi-station production line that will be manned by a few operators such that one operator will have to operate multiple stations, it may be worth considering a U-shape cell as there is likely less walking for operators to do compared to a linear layout and therefore less waste.

For the same reason as above, if you have a process that requires different numbers of operators at different times due to a varying output demand, a U-shape layout will reduce “motion” waste. Imagine the amount of walking involved if one operator is having to attend to a 10-station linear production line.

The available factory floor space or the shape of it might compel you to adopt a U-shape cell

Because of the close proximity of stations, there is easier communication between operators on a U-shape cell compared to a linear one.

When a U-shape layout won’t do, we shouldn’t be afraid to try other arrangements. Linear or I-shaped layouts still have their place and are particularly useful when the production line is short. Access for material feed is also easy.

The L-shaped layout is another layout type which combines some advantages of a linear and a U-shaped layout. It can be a good compromise when your production line isn’t long enough to be arranged in a U shape or if the available floor space can’t fit a U shape layout.

For long automated lines, S-shaped layouts are quite effective as they satisfy the linear requirement of most automated lines and restriction of the length of a factory.

So, when deciding what sort of layout to use for your production line, ensure you are not only thinking “lean” but that your chosen layout actually works for you. Also, don’t forget to consider accessibility for material feed into the line as this will have a major contribution to the success of your layout.