The U-shape layout describes the format of the manufacturing or assembly lines of machines and workstations following the principle of one-piece-flow which is laid out in the shape of the letter "U". The operators are working inside the "U" and with the proper supply of components or material allocation from the outside the movement is reduced to the minimum. The goal is also with the U-Shape layout to have interruption free assembly.

Using “U” Shaped Cells

Generally speaking the u-shaped layout of a manufacturing cell allows operators to easily move from one process step to the other as well as passing on parts or pre-assembled units to the following step with little effort. It is not a necessity to have the U-shaped configuration. This comes mostly from maximizing throughput on less manufacturing space (€/sqm).

The layout of assembly lines in a “U” shaped layout has several advantages:

1. The Start en End are close together, allowing with an installed 2 container mgt. to have full visual control. Following the mizusumashi principle - one operator can handle feeding the line including supply of raw material as well as the transport of finished goods.

2. The shortening of distances allows to share process steps, like in a chaku chaku* line, as well as reducing the wastes of transport and motion.

3. The U-shaped layout provides you the foundation for interruption free one-piece-flow.

4. Transparent and open communication within the work cell is easier.

5. Value adding process is done inside the assembly line, material supply is done from the outside.

6. Following the principles of flexible equipments - high level performance is when your machines and tables are on rollers to have a quick reconfiguration.

7. Typically as mentioned before:, it is less floor space required than with a stretched line, as well as distances for movement are reduced.

Chaku Chaku is a takt flow oriented manufacturing process model. It means load load and describes that one operator follows the complete assembly process - walks with the good - and conducts each assembly process. To learn more about Chaku Chaku read here.