How can you optimize the layout of a production system?

1 Identify the objectives and constraints

The first step in optimizing the layout of a production system is to identify the objectives and constraints that you want to achieve and respect. Objectives are the desired outcomes, such as maximizing the throughput, minimizing the waste, or improving the ergonomics. Constraints are the limitations or restrictions, such as the budget, the floor area, the safety regulations, or the customer demands. You should prioritize the objectives and constraints according to their importance and feasibility, and use them as the criteria for evaluating and comparing different layout alternatives.

2 Analyze the current situation

The second step in optimizing the layout of a production system is to analyze the current situation and identify the problems and opportunities for improvement. You should collect and analyze data on the existing layout, such as the layout dimensions, the equipment locations, the material flows, the transportation distances, the storage areas, the workstations, and the workers' movements. You can use tools such as flow charts, process maps, spaghetti diagrams, or value stream maps to visualize and quantify the current situation. You should also observe and interview the workers and managers to get their feedback and suggestions on the current layout.

3 Generate and evaluate alternatives

The third step in optimizing the layout of a production system is to generate and evaluate different layout alternatives that can meet the objectives and constraints. You can use various methods and techniques to generate layout alternatives, such as systematic layout planning, computer-aided layout design, simulation modeling, or heuristic algorithms. You can also use creativity techniques, such as brainstorming, morphological analysis, or TRIZ, to generate innovative and unconventional layout solutions. You should evaluate each layout alternative according to the objectives and constraints, and use tools such as cost-benefit analysis, multi-criteria decision making, or Pareto analysis to rank and select the best layout option.

4 Implement and monitor the new layout

The fourth step in optimizing the layout of a production system is to implement and monitor the new layout. You should plan and execute the layout change in a systematic and coordinated way, involving all the stakeholders, such as the workers, the managers, the suppliers, and the customers. You should also communicate and train the workers on the new layout, and provide them with the necessary resources and support. You should monitor and measure the performance and impact of the new layout, using indicators such as the productivity, the quality, the safety, or the satisfaction. You should also collect and analyze feedback and data on the new layout, and make adjustments and improvements as needed.

5 Review and update the layout

The fifth step in optimizing the layout of a production system is to review and update the layout periodically. You should not consider the layout as a static and fixed element, but as a dynamic and flexible one that can adapt to the changing needs and conditions of the production system. You should review the layout regularly, and check if it still meets the objectives and constraints, and if it still performs well. You should also update the layout whenever there are significant changes in the production system, such as the introduction of new products, processes, equipment, or technologies. You should use the same methods and tools that you used in the previous steps to review and update the layout.

6 Use electrical engineering software and tools

The sixth step in optimizing the layout of a production system is to use electrical engineering software and tools that can help you design, analyze, and optimize the electrical aspects of the layout. Electrical engineering software and tools can help you calculate the power requirements, select the appropriate cables and wires, design the circuit diagrams, simulate the electrical behavior, and test the electrical safety of the layout. Electrical engineering software and tools can also help you integrate the electrical components with the mechanical, hydraulic, pneumatic, or automation components of the layout, and ensure the compatibility and reliability of the system. Some examples of electrical engineering software and tools are AutoCAD Electrical, EPLAN Electric P8, ETAP, or MATLAB.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?