What are some tips for optimizing facility layout and design in industrial engineering?

1 Identify the objectives and constraints

Before designing or redesigning a facility layout, you need to identify the objectives and constraints of the project. Objectives are the desired outcomes or performance measures that you want to achieve, such as minimizing costs, maximizing throughput, reducing waste, or improving quality. Constraints are the limitations or restrictions that you have to consider, such as budget, space, regulations, or customer requirements. By defining the objectives and constraints, you can set the criteria and scope for evaluating and comparing different layout alternatives.

2 Analyze the current and future processes

Another tip is to analyze the current and future processes that will take place in the facility. This involves collecting and organizing data on the inputs, outputs, activities, and relationships of each process. You can use tools such as process maps, flowcharts, or value stream maps to visualize and document the process flow. By analyzing the processes, you can identify the sources of inefficiency, waste, or variability, and also anticipate the changes or growth that may affect the layout in the future.

3 Choose a suitable layout type

Depending on the nature and characteristics of the processes, you can choose a suitable layout type that matches your objectives and constraints. There are four main types of layouts: product layout, process layout, fixed position layout, and cellular layout. Product layout arranges the equipment and resources according to the sequence of operations for a specific product or service. Process layout groups the equipment and resources according to their function or similarity. Fixed position layout keeps the product or service in one place and brings the equipment and resources to it. Cellular layout divides the facility into small units or cells that can perform a complete or partial process for a product or service family.

4 Apply layout design techniques

When selecting a layout type, you can use various layout design techniques to optimize the arrangement and allocation of the equipment and resources. CRAFT (Computerized Relative Allocation of Facilities Technique) is a computer-based method that uses an initial layout and a matrix of interdepartmental costs or flows to generate and evaluate alternative layouts. SLP (Systematic Layout Planning) is a manual procedure that consists of relationship analysis, space analysis, activity analysis, and relationship diagramming to develop a layout based on the closeness ratings of the departments. ALDEP (Automated Layout Design Program) is a computer-based technique that uses an activity relationship chart and a set of construction rules to create and improve a layout. CORELAP (Computerized Relationship Layout Planning) is another computer-based method that uses an activity relationship chart and a space availability chart to create and improve a layout.

5 Evaluate and implement the layout

The final tip is to evaluate and implement the layout that you have designed or selected. You can use quantitative and qualitative methods to assess the performance and feasibility of the layout, such as cost-benefit analysis, simulation, or stakeholder feedback. You can also use tools such as CAD (Computer-Aided Design) or VR (Virtual Reality) to visualize and test the layout before implementing it. Finally, you can plan and execute the implementation process by following the best practices of project management, such as defining the scope, schedule, budget, and quality, and monitoring and controlling the progress and outcomes.

6 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?