Plant Layout, Facility Layout, Factory Design, Floor Plan

Plant Layout, Facility Layout, Factory Design, Floor Plan

Layout, or the physical organization of people, materials and machines within a workspace, is at the very heart of productivity.

For an existing business of any type, a revised layout can often cut operating costs and add capacity.

For a new facility, design and layout are critical to optimize construction cost yet provide for long term operating efficiency and room for growth.

By analyzing and improving workspace layout, it is possible to
• Simplify and reduce product and personnel movement
• Optimize product flow through the process, make it visible
• Add output, capacity and utilization by relieving space constraints
• Reduce handling and damage to product
• Simplify organization of material and equipment
• Allow for future growth

Jackson Productivity Research has developed many layouts which reduced costs, improved flow, and allowed for later modification.


Reasons for another layout
The two primary reasons for creating a new layout are because a facility addition requires it; or to generate a better flow pattern for materials and / or people in an existing area.

In either case, it is important first to define the requirements for use of the space, the contents, major access points, building limitations, regulations affecting the space including floor loads, rest rooms, fire codes and emergency routes. Then, plot several options, discuss them with the stakeholders, and choose an efficient, safe, long lasting one with good flow.

The type of inventory system in use is also a major factor early in a manufacturing layout. Will material be supplied Just in Case, the traditional Materials Requirement Planning technique, or will it be delivered Just In Time? Know what system you will use, in order to assign the correct amount of space to materials, in the appropriate places.

A recent client believed that his current layout did not reflect management’s desire for employees to enjoy their working environment, and we created much less cluttered, more safe, conditions with a layout. He also wanted to be able to show off the highly capable modern equipment to his potential customers; that is possible today.



Flow
A good flow pattern for materials and people should be a driving force for any layout. It may not be possible to quantify the benefits, but many productive practices follow from a careful layout; materials movement without retracing steps, visibility of inventory and of work, easy access of direct and support people, superior material handling, safety, housekeeping, emergency routes.

A prerequisite to a layout is to define material handling into an area, considering material dimensions and weight, overhead lift, trucks, conveyors, etc. Also determine how utilities will be provided, because while overhead supply is much easier it also can block access to equipment and interfere with sight lines and vision.

Layout implementation
Layouts tend to be fixed in place for a long time, because a new one can be expensive and cause disruption as it is installed. And too, a layout will probably be obsolete soon after it is put in due to new equipment or product or a shift in volumes. There is no magic solution to this dilemma, unless your crystal ball is clearer than mine. If possible, try to create “pockets” of empty floor space in the layout, with nothing physically installed there. Then when a new requirement arises, you will have room to maneuver.

Some re-layouts are easier than others; if utilities such as water and drains are under a concrete floor, a change will be long and expensive. Many modern building provide utility access from the ceilings, even drains, and changes can be accomplished much more readily and swiftly. If possible, place really permanent objects together to minimize the obstructions to expansion.

The classic method to gain room is to move into storage space, warehouses for instance. That often can be a practical option, especially if a concurrent objective is to reduce inventory.


A building addition
When a new area is to be laid out and built, be sure to address not only the immediate need but also the future as well as it can be anticipated, to keep the layout effective for some time. If the budget allows, build in extra space to provide options for future actions. Be sure to plan where a major expansion will be even if it is not built until later. Then in the layout do not block later access to the expansion route with permanent facilities such as docks, rest rooms, steam generators, water treatment equipment.

Plan the building layout before setting the design for the facility because existing walls and access points restrict flow and placement of equipment.

Jack Greene, Jackson Productivity Research Inc.



Plant Layout, Facility Layout, Factory Design, Floor Plan - To learn more about this author, visit Jack Greene's Website.

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