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What is the importance of a factory layout?


Factory layout


The layout that has the arrangement of equipment and machines inside a manufacturing area in a factory is a factory layout. Architects prepare the factory layout to understand the space needed for equipment, the material flow and man movement. 


While preparing the factory layout, the architects have to consider the following: 


  1. Availability of space
  2. Final product
  3. Material movement 
  4. Safe working practices
  5. Convenience of operations
  6. Effective workflow
  7. Optimised space

Plant layout is a very critical decision in the design stage. The preparation of a factory layout is a well-thought-out process. It requires a lot of brainstorming sessions to optimise the workflow. It is a challenge to change the layout after the facility is constructed. Moreover, the change is expensive too. Hence, the layout has to be adequately discussed. The project stakeholders must look for roadblocks and find solutions for them. 


The factory layout is a medium to long-term investment. Hence, it needs a optimal planning.


The factory layout could be for a greenfield project, a brownfield project, when a new product/ equipment has come up or when a product is withdrawn from the market. 

Architects and engineers


Criteria for Factory layout design


The architects consider the following while designing a factory layout: 

  1. Raw material storage
  2. Finished goods storage
  3. Sequence of process
  4. Consumable storage
  5. Man movement
  6. Waste storage
  7. Provision for future expansion
  8. Space optimisation
  9. Safety
  10. Flexibility 
  11. Optimised capital. 


The factory layout typically shows the following areas: 

  1. Production building
  2. Shop floor
  3. Other manufacturing areas
  4. Warehouse
  5. FG and RM Storage
  6. Scrap Yard
  7. Material handling equipment
  8. Material travel route

Benefits of factory layout


  1. Clash detection at the site is minimal
  2. Safe and appropriate width for man and material movement
  3. The proper location for the extraction unit 
  4. Placement of signages more accurate.
  5. Better equipment alignment
  6. Escape routes well planned
  7. Efficient use of space
  8. Flexibility in layout
  9. Lead times are down
  10. Minimal material handling 

Finally, architects must emphasise the need for a well-laid-out factory layout. 

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