Designing a new factory: How the right configuration reduces costs

The proper layout and design of a new factory can be critical to both efficiency and productivity, as well as its overall success. A proper layout of a new factory improves the flow of materials, operations, as employees perform their tasks more easily and quickly, reduces delivery time and errors, and increases product quality.

Over time, a well-designed production space leads to significant cost savings, thanks to less equipment wear, lower energy consumption, and greater flexibility in meeting future needs.

The Basics of Efficient Factory Design

Properly designing a factory space is a matter of functionality, efficiency, and safety. There are specific principles that must be followed so that the layout of the space supports the needs of production and ensures the best possible operation.

Efficient Workflow

It may sound like a small thing, but the flow of materials and products is important when designing a factory layout. The distance that materials and products travel between each production stage is very important for the time you spend. To waste as little time as possible, it is important to base the arrangement of machines and workstations on creating a smooth flow of materials and products.

For example, placing machines in the same production stage next to each other can reduce the distance that materials and products travel between each machine. In addition, arranging workstations in a linear arrangement can help reduce the distance traveled by materials and products.

Optimal utilization of space

Proper design ensures optimal use of available space without waste. Therefore, it is vital to be aware of the “hidden spots” within your facilities as there may be areas where resources are underutilized without being immediately apparent. One way to make the most of all the available space in your factory is to use space-saving machinery and equipment that can perform multiple functions. This helps to reduce the number of machines and equipment required, saving space and reducing costs.

Another smart way to optimize space utilization is to use vertical space. This can be achieved by using mezzanines or installing storage racks. By using vertical space, you can increase the amount of usable space in your factory without having to expand the factory floor area.

Reduced unnecessary movement of workers for faster flow

The correct layout of the factory allows workers to perform their tasks with less unnecessary movement within the space. When workstations and machines are placed in a logical order, i.e. based on the production process, unnecessary movements are reduced and valuable time is saved. Workflow becomes faster and more organized, while workers focus on their core tasks without unnecessary delays.

Ergonomics and Safety

Safety is always a top priority in any factory. When designing a factory layout, it is important to consider the safety of both workers and equipment. This can be achieved by positioning machinery and equipment in a way that minimizes the risk of accidents.

For example, machinery that produces loud noises or emits hazardous gases should be placed in a separate room or enclosed in a soundproof or ventilated chamber. In addition, workstations should be designed to minimize the risk of repetitive strain injuries and other ergonomic issues.

How do you design a successful factory?

The first step to designing a successful new factory is to map out your goals and requirements. Clearly define the goals of your factory layout design, whether it’s maximizing efficiency, reducing lead times, or optimizing storage.

If your factory is already up and running and you want to optimize it, then the next step is to understand your current workflows. This means describing your processes, identifying bottlenecks, and determining the optimal sequence of tasks.

Once you’ve got your workflow clear, the next step is to gather detailed information about your resources: space, equipment, and workforce. With this data, it’s easier to create simulations of various layout options to visualize different setups and how they could affect your production efficiency.

The design of a new factory affects every aspect of a business’s operations. From smooth material flow to cost reduction and enhanced safety and productivity, a smart layout can make all the difference. By investing in the right design from the start, businesses are laying the foundation for long-term sustainability, flexibility and growth.