When starting to factory design for an industrial construction project, there are many factors to consider before operating a production facility. Investors are always looking for ways to accelerate construction progress, improve production efficiency, and increase future profits. By optimizing the factory space effectively, architects can help investors achieve all of these goals.
The layout of the factory space is often overlooked, even though it offers significant potential for cost savings in production. In this article, let’s explore space optimization and the benefits it brings to the design process of factory layouts.
Factory space refers to the preliminary layout and division of essential equipment and components of the production facility, which is carried out using 2D CAD software.
Architects will use the actual dimensions of the equipment and facilities to create a scaled model of the factory. If actual dimensions are not used, the final design will not be as effective as desired.
In many cases, architects will present the final design with a 3D simulation that provides an overview, allowing observation of the equipment in operation and understanding how it functions in reality. Since everything is modeled to scale, investors can assess the distances between equipment, walkways, and many other factors.
Designing the factory allows investors to calculate the necessary equipment or build storage warehouses. This also enables architects to easily adjust the layout flexibly according to needs.
- Material flow: The flow of raw materials within the factory needs to be optimized to minimize operational time and costs.
- Equipment and materials: The location and size of machinery, equipment, and materials affect the workspace layout.
- Factory floor plan: The shape and size of the factory serve as the basis for designing the layout.
- Distance between production areas: A reasonable distance between production zones must be ensured to facilitate movement and work.
- Production processes of the industry: The specifics of each industry will determine the layout of the production line and functional areas.
Optimizing space in the design of manufacturing facilities is a process where architects seek to make the most efficient use of every area in the design. This includes integrating optimization and lean principles into the floor plan to minimize wasted space and maximize movement flow.
An important principle for optimizing space is to designate areas for each production stage. Each production stage (e.g., cutting, arranging, packaging) will be carried out in a separate area. This helps group related equipment and personnel closer together, reducing travel time and increasing work efficiency.
The optimization of the flow of materials and products must be designed to be seamless and non-overlapping, helping to minimize transportation time and the risk of product damage.
The characteristics that determine whether a factory space is well-optimized depend on the needs and activities of the factory. However, there are some important features to pay attention to:
- Efficient use of space: The area of the factory is a fixed factor that will limit the activities of the factory. Therefore, architects must make the most of the available space to build systems and delineate production areas.
- Accessible factory design: The layout of the components must ensure sufficient space between equipment to guarantee accessibility. Operators need adequate workspace to ensure occupational safety as well as the process of transporting goods within the factory..
- Flexibility for future expansion: Ensure that the floor plan is not restricted if the investor wishes to expand the factory in the future. Many manufacturing workshops often anticipate the possibility of expansion by 20-40%.
- Suitability for the factory's production activities: The arrangement of workspaces must align with the specific activities of the business. There is no one-size-fits-all factory design solution applicable to all industrial sectors, and the layout must also be adjusted to fit the production and operational processes of the business.
Why do businesses spend so much time optimizing their factory space? Here are some of the most important reasons:
Reduce production time: A well-optimized workspace facilitates workflow, reduces production time, and enhances efficiency.
Increase operational speed: Organized processes help shorten transportation distances and create favorable conditions for faster and more effective work.
Maximize usable area: Before actual implementation, businesses can experiment with various layout options on the factory design drawings, thereby saving space and costs.
Visualize and adjust processes: With a design diagram, businesses can easily identify unreasonable points and make improvements before execution, minimizing errors.
Increase profits: By combining all these factors, investors not only save time and resources but also enhance output, contributing to revenue growth.
By simulating the actual dimensions and operational speeds of each type of machinery, BIC closely collaborated with the technical team to improve the production process. The results yielded significant improvements:
- 10% reduction in usable area
- 10% increase in production efficiency
- 10-fold reduction in defective products
- 20% acceleration in construction progress
- Total project cost savings: $879,000 (~15%)
Thanks to the strategy of optimizing production factory design, the business not only enhanced production efficiency but also significantly saved on investment costs.
Have you understood how to plan and design the optimal layout for your factory? With BIC, designing an efficient factory is more intuitive and easier. Contact BIC today to get started and explore the design solutions that best fit your business.
