The Strategic Role of Plant Layout in Lean Manufacturing: A Review of Principles, Digital Integration and Sectoral Applications

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As the global manufacturing landscape undergoes rapid transformation, organizations are compelled to enhance productivity, reduce waste, and strengthen competitiveness. Lean manufacturing has emerged as a critical methodology to achieve these objectives, fundamentally shifting how businesses approach production by eliminating non-value-adding activities, pursuing continuous improvement, and utilizing resources efficiently. Within this paradigm, the design of plant layouts plays a pivotal role, serving as the foundation for operational efficiency through optimized workflow, reduced transportation, and effective space utilization. This review paper examines the multifaceted relationship between plant layout and lean manufacturing, tracing its evolution from the Toyota Production System to contemporary Industry 4.0-enabled smart factories. The paper explores foundational lean principles, various layout typologies, integration with lean tools such as 5S, Kaizen, and Kanban, and the emerging influence of digital technologies including digital twins, the Internet of Things, and artificial intelligence. Furthermore, it addresses human factors and ergonomics, environmental sustainability through green lean approaches, sector-specific applications, and persistent implementation challenges. By synthesizing insights from academic literature and industry case studies, this paper provides a strategic framework for researchers, practitioners, and policymakers seeking to leverage layout design as a driver of lean transformation and long-term operational excellence.

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