Using Six Sigma DMAIC Methodology to Develop a Facility Layout for a New Production Line

To have an efficient and effective production system, it's crucial to give special attention to the layout of the facility. The main aim of this study is to use the Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC) methodology to assess and improve the performance of an existing layout. Each phase will be discussed illustrating the basic engineering tools that will be used to achieve the project's objectives and identify the optimal layout design. The main results achieved were identifying the best layout design from four developed layout alternatives and choosing the optimal one that has the lowest cost and highest efficiency. In conclusion, by achieving the study objectives, we enhanced the working environment by applying facility planning tools to streamline the production processes and improve efficiency, performance and safety of the factory layout.