Factory design plays a crucial role in ensuring smooth and efficient production processes. However, it goes beyond just rational space planning, as it also involves compliance with technical and safety standards. Many businesses encounter common mistakes during the design phase, from insufficient site surveys to using inappropriate materials, leading to increased costs and extended construction times. In this article, BIC will help you identify common factory design mistakes and how to avoid them, ensuring a successful project from the start.
Design errors in factories not only affect the construction quality but can also lead to severe consequences throughout the building’s lifecycle.
- Reduced building lifespan: Design mistakes such as inaccurate load calculations or using substandard materials can result in the structure deteriorating sooner than expected. Problems like cracking, subsidence, and structural failures will shorten the factory’s lifespan, leading to costly repairs and maintenance in a short period.
- Increased operational and maintenance costs after the factory begins operation: Design flaws often result in more repairs and maintenance than anticipated. For example, an electrical system that does not meet standards may cause frequent issues, increasing maintenance and repair costs. Inefficient water supply and drainage systems can lead to pollution and blockage problems, raising operating costs.
- Impact on worker safety and productivity: A substandard design can reduce work efficiency and jeopardize worker safety. For instance, poor layout can increase the risk of accidents, while inadequate ventilation and lighting systems can affect workers' health and productivity. These issues not only decrease production efficiency but also negatively impact the working environment.
Focusing on factory design from the outset can help you avoid these serious consequences and ensure the facility operates efficiently, safely, and sustainably.
In factory design, poor site planning can lead to serious issues that directly impact the efficiency and safety of production processes.
- Poor layout design:
One of the common mistakes is the unscientific arrangement of machinery and equipment. When machines are not properly placed, the workflow is disrupted, affecting the production process and reducing overall efficiency. This also increases maintenance and repair time, as workers must move between inconveniently located areas.
The distances between different areas in the factory must be carefully considered. If the distances are not optimal, congestion can occur, reducing the mobility of workers and equipment. This is especially problematic during peak production times, increasing the risk of accidents and reducing work efficiency.
Narrow pathways within the factory can also create major obstacles to production processes. Narrow pathways may cause traffic issues inside the factory, slowing down work progress and increasing accident risk. This not only affects productivity but also worker safety.
- Inadequate ventilation and lighting systems:
These are critical factors that cannot be overlooked in factory design. If the ventilation system is insufficient, the air inside the factory becomes stuffy, affecting workers' health and reducing work efficiency. Similarly, poor lighting systems make tasks more difficult and can lead to accidents during production.
- Non-optimal storage space:
Poorly designed storage spaces create difficulties in managing goods and raw materials. When there isn't enough storage space, workers will have to move and arrange goods inefficiently, leading to wasted time and resources. This can also result in the loss or damage of goods, affecting the overall efficiency of the factory.
- Inaccurate load calculations: Inaccurate load calculations in factory design can lead to structural components being unable to bear the load, causing subsidence or cracks in the building. Loads include the weight of the structure, machinery, equipment, and goods. If not calculated correctly, these elements may exceed the foundation’s and structural components' capacity, resulting in serious issues.
- Poor-quality materials: Using substandard materials in structural design can severely affect the building's durability and lifespan. Materials such as concrete, steel, or bricks that do not meet quality standards will not provide sufficient load-bearing capacity, increasing the risk of cracking, failure, or collapse. Poor-quality materials can also lead to increased future maintenance and repair costs.
- Failure to account for external forces: A structural design that does not account for external forces such as wind, earthquakes, and temperature fluctuations can result in a building unable to withstand environmental impacts. Strong winds can exert pressure on the structure, earthquakes can cause violent shaking or collapse, and temperature changes can cause materials to contract or expand. If these factors are not considered, the building may become unsafe and unsustainable under extreme conditions.
- Non-standard installation: When the electrical system is not installed according to standards in factory design, it can lead to severe issues, including fire hazards and electrical leakage. Common mistakes include using substandard wiring, insecure connections, or a lack of overload protection. These issues not only threaten worker safety but can also cause significant damage to property and equipment. A non-standard electrical system also increases future maintenance and repair costs.
- Subpar water supply and drainage systems: A poor-quality water supply and drainage system can lead to issues related to sanitation and environmental pollution. If the water supply system is not designed and installed correctly, water may become contaminated or insufficient for production needs. A poor drainage system may cause blockages, leading to untreated wastewater problems, polluting the surrounding environment, and affecting public health. Neglecting water systems can also lead to breakdowns and reduce the overall efficiency of the facility.
- Lack of or insufficient equipment: In factory design, a fire protection system lacking or missing essential equipment makes it difficult to extinguish fires. Basic fire protection equipment, such as fire extinguishers, fire hoses, and sprinkler systems, must be fully installed and strategically placed to respond promptly to emergencies. Insufficient or ineffective equipment may prevent quick fire control, increasing the risk of damage to people and property.
- Non-functional fire alarm system: A fire alarm system that does not work or is not fully installed delays the detection and response process in case of a fire. The fire alarm system, which includes smoke detectors, heat sensors, and alarm bells, plays a crucial role in early warnings so workers can evacuate dangerous areas and firefighters can arrive in time. If the fire alarm system does not function properly, delayed detection will reduce the ability to control and respond to fires, leading to more serious consequences.
Professional factory design plays a critical role in ensuring the facility operates efficiently and safely. Reputable design companies can help you avoid these common mistakes and provide the best solutions for your project. Investors are advised to choose an experienced and trusted design firm. Don't hesitate to contact BIC to ensure your factory design meets your needs and standards.
