Enhancing Flow and Reducing Waste: A Lean Relayout at Lowara S.R.L.

This thesis explores the lean transformation journey of Lowara S.R.L., a company leader in the production of hydraulic pumps, water treatment and control systems, focusing on the relayout of an assembly line through the application of lean manufacturing principles. The study addresses key issues such as high inventory levels, inefficient space utilization, and the need to meet production demands while trying to transition from two shifts to one. The research begins by analyzing the AS-IS situation, identifying inefficiencies in the existing assembly line layout, documenting the operational challenges faced by the company and mapping all the flows that are linked to the line. Using lean tools like Value Stream Mapping (VSM), continuous flow, poka-yoke, Kaizen, etc, the study proposes a comprehensive relayout designed to improve workflow, reduce waste, and optimize production capacity. The TO-BE situation is presented as the target state, highlighting improvements in space utilization, inventory reduction, and enhanced production flow. The relayout is expected to align the company's operations with lean manufacturing principles, resulting in a more efficient assembly process that can meet demand with reduced shifts. The aim is to create and comprehend the logic of the “model cell”, that will be then applied and suited to the other cells of the plant. The findings demonstrate that the lean transformation not only improves operational efficiency but also contributes to sustainable growth by minimizing waste and maximizing value. The thesis concludes with an analysis of the challenges encountered during implementation, lessons learned, and recommendations for further lean improvements at Lowara S.R.L.