How do you evaluate the impact of a new equipment installation on the plant layout?

Why cant we install machines anywhere in a given space? What is point of a layout? Tighter the machine space, more machines, more production can be extracted from the same floor space, what is the point in having a layout? Our known competitors/neighbors run an cheaper, more efficient operation with apparently lowest costs. Are these above statements true or are there some unseen elements of in-efficiency and costs?

When the gap between income and expenses keep shrinking, the only way forward is to increase production efficiency. Do we understand elements related to increasing production, reducing wastages, operability time longevity, maintenance downtimes and utility savings from our machines?

Before proceeding with the installation of new equipment, it's imperative to evaluate its impact on the plant layout. This begins with a thorough understanding of the equipment size and specifications. Conducting a comprehensive site survey to assess the availability of space and access points for installation is essential. Factors such as clearance requirements, proximity to existing infrastructure, and potential obstructions must be carefully considered to ensure a seamless integration into the plant layout. By carefully evaluating these aspects upfront, potential challenges can be identified and addressed proactively during during the plant layout finalisation.

If the size or complexity of the equipment makes it challenging to install in one piece, splitting it into modules or skids could be a viable solution. This approach allows for easier transportation, maneuverability, and assembly on-site. By breaking down the equipment into manageable components, it becomes more feasible to navigate through tight spaces or obstacles within the plant layout. Additionally, modular installation with orientation as per the layout availability at site can expedite the overall installation process, reducing downtime and accelerating the realization of operational benefits. In addition to this it also address logistical challenges and ensuring the successful integration of the new equipment into the plant layout.

Based on the process and machinery needed for the activities in the business plan, the layout needs to be engineered considering 1) Material Flow which include RM (Raw materials), WIP (Work in progress) across machines & FG (Finished Goods) across the entire layout floor seamlessly with critical path flow and minimum handling. 2) Machine Space for operation, maintenance and utilities. 3) Man Flow routes and positioning to maximize time and work study in the operation and maintenance of the machines.

Proven techniques are the best way to achieve quick results, however innovation is rarely found in repetition. Every business and machine shop layout has it's own unique element that is best known to managers of the operations. It is important to take feedback, possible layout ideas and understand the unique proposition that is crucial to the business. These elements combined with intelligence gathered through experience at varied industries helps us develop a layout that is unique, innovative and with proven techniques.

With a deeper understanding of the elements: 1) Unique proposition of the business/work-cell 2) Sequence and process flow diagram 3) Material flow with data and expectations 4) Space available in plan and elevation views 5) Machine data and capacity balancing 6) Maintenance and utilities servicing areas 7) Material handling system and equipment 8) Operator (HMI) Human Machine Interfaces and their flow 9) Controls and KPI measurements of improvement 10) Sustainability of the layout through years of growth ahead. 11) Safety and risk assessments These elements with clear definition of the requirement from the layout will help develop a system layout requirement sheet.

Brainstorming potential risks such as narrow passages, sharp turns, or weight restrictions allows for proactive risk mitigation strategies to be developed. By thoroughly analyzing the existing road layout and considering constructability factors, project teams can anticipate and address logistical challenges before they arise. Conducting a thorough mechanical handling study includes assessing crane capacities needed for lifting and positioning the equipment which is essential to evaluate the machinery required for transportation and installation, as well as identifying availability in the market. Additionally, estimating the time required for transportation and installation at the site in meeting project timelines and avoid further delays