In an increasingly globalized environment, companies must ensure their profit margins through meticulous attention to detail. Therefore, it is imperative to carefully evaluate through proper plant design and layout all aspects of what, how, with what, and where to produce or provide a service, as well as the details of capacity to achieve optimal facility performance.
Plant Layout Maintenance
In an increasingly globalized environment, companies must ensure their profit margins through meticulous attention to detail. Therefore, it is imperative to carefully evaluate through proper plant design and layout all aspects of what, how, with what, and where to produce or provide a service, as well as the details of capacity to achieve optimal facility performance.
This applies to any situation requiring the arrangement of physical resources in a specific space, thus it can be applied to both industrial processes and service facilities.
What is Plant Layout?
Plant layout is defined as the physical arrangement of the elements that make up a facility, whether industrial or service-oriented. This arrangement includes the spaces required for movements, storage, direct or indirect collaborators, and all activities taking place in the facility. A plant layout can be applied to an existing facility or one under development.
Objectives of Plant Design and Layout
The objective of plant design and layout work is to find an arrangement of work areas and equipment that is the most cost-efficient, while also being the safest and most satisfactory for the organization's collaborators. Specifically, the advantages of a good layout result in reduced manufacturing costs through the following benefits:
- Reduction of Occupational Health Risks and Accidents:
- Safety considerations are integrated into the design and layout, eliminating tools from walkways, hazardous pathways, reducing slip probabilities, unsanitary conditions, poor ventilation, and inadequate lighting.
- Improved Worker Satisfaction:
- Detail engineering in design and layout addresses minor issues affecting workers, such as direct sunlight and workplace shadows, which, when resolved, increase worker morale as they feel the management cares about their well-being.
- Increased Productivity:
- Many factors positively affected by good design and layout work contribute to overall productivity, such as minimizing movements and increasing worker efficiency.
- Reduction of Delays:
- By balancing operations, it prevents materials, workers, and machines from waiting. It is a fundamental principle to ensure production units do not touch the ground.
- Space Optimization:
- By minimizing travel distances and optimally arranging aisles, storage, equipment, and personnel, space is better utilized. Utilizing multiple levels is a key principle to take advantage of the third dimension, saving surface area.
- Reduction of Work-in-Process Material:
- By shortening distances and creating logical production sequences through layout, material remains in the process for less time.
- Optimization of Supervision:
- The design includes planning for visibility needed for supervision purposes.
When is a New Layout Needed?
There are various indicators that signal the need for a layout change. The most logical time to consider a layout change is when improvements are made to methods or machinery. Good layouts are designed based on machinery and equipment, which are based on processes and methods. Therefore, whenever a layout initiative is proposed, methods and processes should be reevaluated in the initial stage. Likewise, whenever new methods are adopted or new machinery installed, it is a good time to reassess the layout. Specific conditions that may necessitate a new layout include:
- Receiving Department:
- Material congestion.
- Administrative issues in the department.
- Delays of supplier vehicles.
- Excessive manual handling or rehandling.
- Need for overtime.
- Shipping:
- Delays in dispatches.
- Breakages or losses of materials.
- Environment:
- Inadequate lighting, ventilation, noise, and cleanliness conditions.
- High accident rates, incidental occurrences, or sudden changes in trends.
- High staff turnover.
- General Conditions:
- Chaotic production schedule.
- High indirect costs.
- Production Expansion:
- Many small production plants today will become medium-sized factories tomorrow. This growth will be gradual and continuous, and plant layout should always be considered in the organization’s strategic planning.
- New Methods:
- Even if new products use existing processes, new handling challenges will likely arise. Additionally, there will be increased pressure on the available manufacturing space.
- New Facilities:
- The main function of a new facility is to allow for a more efficient layout. In this case, there is an opportunity to eliminate structural and design aspects that restrict optimal operation. The design of the new building should facilitate the necessary growth and expansion.