Plant Layout Design | Manufacturing Factory Layout Plan
Optimize Your Plant Layout and Design for Space Efficiency and Cost Savings
- 30% Additional Space Efficiency
- 10% Reduction in Manufacturing Cost, FIFO
- 20% Reduction in RM, WIP, FG
250+
Projects
25+
Industries
Area Covered
1,35,63,250 Sq Ft
Area Optimised
40,68,975 Sq Ft
Plant layout design is the methodical arrangement of equipment, procedures, and services inside a manufacturing facility. The primary goal is to optimize overall Space Efficiency while simultaneously producing the highest quality output in order to maximize production efficiency. This covers every aspect of creating an economical and effective working environment for a Manufacturing Factory Layout Plan, also known as a Factory Plant Layout Design Services.
Tetrahedron has wide range of experience in setting up 100+ Greenfield Plant Layout Projects (New Plant Set-Up) and 150+ Brownfield Plant Layout Projects (Creating space within existing infrastructure, whether through major changes or minor adjustments), helps manufacturing companies in implementing Good Manufacturing Practices (GMP).
Benefits of Plant Layout Design
30% Space Creation In Existing Infrastructure
20% Reduction in Distance Travel by Material
100% Workplace Safety Based Plant Layout
50% Reduction in Machine Set-Up & Change Over Time
10% Reduction in Inventory Level and Inventory Space
20% Reduction in Material Handling Equipment Usage
Zero Line Stop Due to Material Unavailability
Visual Factory For All Activities and Process
Proper Lighting & Usage of Natural Light
Prepare For Future Changes and Enablers
Serving These Manufacturing Industries
Lean Plant Layout Development Approach
When developing a Lean Plant Layout design, meticulous planning and careful analysis are required to increase space efficiency. Before designing, it is important to analyze the management requirements and thoroughly understand the production process. Following that, we can proceed with data collection, process mapping, and analysis. So we have a proven approach consisting 8 steps that will help to create the plant layout design conceptual with optimized output, reduce expenses, and foster a secure work environment.
Advantages of Tetrahedron's Lean Layout Approach
A Plant / Factory layout design should be valid for at least 5 Yrs.
Factory Layout Design is a critical investment for any manufacturing company, and a flow-focused – effective layout impacts business performances and profitability. Once a layout is frozen it’s almost impossible or very cost-intensive to change the layout especially after the civil works are completed.
Tetrahedron considers these facts and tries to create multiple (4-5) simulation wherein the client can select the best possible layout with existing business requirements as well as all possible future plans.
3D Plant Layout
Visualize how 3D simulations created by Tetrahedron works as a perfect bridge between the Concept Level Layout and Final Post Construction layout. Tetrahedron uses multiple software for layout design and 3D simulations, that helps the clients to visualize how the future plant is going to look like post-implementation of Lean Layout with (GMP) Good Manufacturing Practices.
An effective manufacturing factory layout plan is indispensable if production is to be efficient and costly. Our plant layout consultants excels in individually tailored plans that improve workflow, ensure safety, and maximize space utilization.
Business & Operational Performance Planning
Tetrahedron takes into consideration lean manufacturing practices and design layouts that will help to –
(1) Improve Line Balancing
(2) Improve Manpower Utilization
(3) Plan and Optimise Inventory
(4) Calculate Manpower Requirements
(5) Reduce Material Handling Equipment Requirement
(6) Improve Space Efficiency
(7) Good Manufacturing Practices
Get Factory Audit to reduces gaps cost-effectively
Our company stands out in delivering comprehensive factory audit services, utilizing our expertise to guarantee compliance with the most current standards and regulations. We specialize in conducting detailed plant layout audits that prioritize optimizing existing infrastructure by strategically creating space and reducing material travel distances. Through careful evaluation of your current layout, we pinpoint inefficiencies that impact workflow and productivity, offering practical recommendations for enhancement.
Whether you’re designing a new facility or optimizing an existing layout, our audits provide actionable insights to ensure your design meets industry standards and operational goals. We provide factory auditing services at very affordable costs. We are recognized as the trusted factory audit consultants in Noida.
What is Visual Management System?
Visual Control and Visual Displays are used to visually operate a manufacturing facility called Visual Factory. Visual Management helps employees or workers to get quick information about the workplace and tasks being completed. Benefit of creating visual displays in your organization is to “Encourage workers to feel a feeling of responsibility for the workplace”. So that management can make decisions quickly based on the information.
How to create Visual Management in Manufacturing Business
In order to set up Visual Management in the manufacturing business, we have to train employees/workers, implement new solutions, and ongoing effectiveness monitoring is required. Visual Management involves strategically placing visual cues like signages, color-coded floor markings, and specified work areas to maximize productivity and safety that helps in maximizing productivity and safety.
MEP Engineering and Design Services in Plant Layout Design
We offers comprehensive consultancy and design services for MEP (Mechanical, Electrical, and Plumbing) systems as part of our plant layout design solutions. Our expertise includes designing efficient water supply and distribution systems, plumbing and drainage networks, and advanced firefighting plans.
We specialize in system design, equipment selection, and complete installations, including HT and LT works. Our services also encompass the preparation of detailed engineering drawings, cost estimates, and tender-ready design documents.
The M-E-P in MEP engineering are:
1. Mechanical Engineering
1.1 HVAC System Design:
Air Handling Units (AHUs): Selection and specification of AHUs to provide adequate airflow and temperature control.
Filtration: Design and installation of High-Efficiency Particulate Air (HEPA) filters to maintain cleanliness standards.
Temperature and Humidity Control: Precision control systems for maintaining required temperature and humidity levels within the cleanroom.
Airflow Distribution: Design of ductwork and diffusers to ensure uniform air distribution and prevent contamination.
1.2 Cleanroom Suitability:
Pressure Control: Implementation of positive pressure systems to prevent ingress of contaminants.
Airflow Patterns: Design of laminar flow and unidirectional airflow systems to minimize contamination.
1.3 Maintenance Access:
Accessibility: Design for ease of maintenance with appropriate access points for filters and other critical components.
2. Electrical Engineering
2.1 Power Distribution:
Circuit Design: Specification of electrical circuits to support cleanroom equipment and lighting.
3. Plumbing Systems
3.1 Water Systems:
Clean Water Supply: Design of water systems to ensure clean and contaminant-free water supply for the cleanroom.
3.2 Specialized Plumbing:
DM Water Systems: Design and installation of ultrapure water systems if required for cleanroom operations.
With a commitment to quality and sustainability, we help manufacturers streamline processes, improve employee comfort, and reduce downtime that helps in your plant’s performance.
Case Study
Lean Layout In Fettling Operation
(Leading Global Automotive Part Manufacturer)
Challenges
Before Tetrahedron–
- Operating as a batch process fettling operation leading to huge WIPs
- Frequent delivery failures due to unavailability of finished goods.
Approaches
Tetrahedron conducted a Time & Motion Study for Shot-blasting to painting operation of the fettling line with a target to develop a Lean Line with 5 years capacity projection. The result achieved in 6 months.
Results
- 3 Shifts (24 Hrs) operation reduced to 19 Hrs
- Line Balancing Implemented – Sequential Flow of Goods, FIFO
- Line formation with exact manpower requirement with projections
- Identified 20+ Simple Automation
- Multiple Operation by single workman by formation improvement
- WIP reduced by 50%
Green Field Layout Of Glazing Division
(India’s Largest UPVC Manufacturer (Bhiwadi))
Challenges
Before Tetrahedron-
- High Cost due to High Manual Manufacturing
- Low Productivity due to non standardized product
- High WIP because of Material Handling
- High Manual Packaging leading to high labor Costs
Approaches
Tetrahedron studied the entire production line and helped to identify at least 43 opportunities to implement automation. With this in mind, 17 high-impact projects were taken on.
Results
- 36% Manpower Reduction
- Ideation and Implementation of end to end Material Handling
- Material Handling breakages reduced by 70%
- 40% Line Productivity Enhancement
Testimonials
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LOA from Clients
FAQ's
What is Lean Plant Layout ?
Lean Layout is the ideas and techniques for total elimination of waste. The goal of Lean Layout is to increase efficiency, productivity and flexibility in the production process for full utilisation of Cubic space, Machinery, Manpower to increase Productivity and Profit with Zero Waste.
What is the best layout for lean?
It depends on the type of manufacturing company, product, material used ,machinery and many more factors. Our experts guide you according to your company and suggest best layout for you.
How do I optimize factory plant layout design?
You can optimize your Factory plant layout design by effectively utilisation of vertical and horizontal space, WIP Inventory reduction, Material and Manpower movement reduction on shop floor, Better Natural lighting and ventilation.
What are the 4 primary plant layout methods?
A successful factory layout design takes safety precautions, equipment placement, workflow efficiency, and space utilization into account.
Does Plant layout design also includes Safety aspects in shop floor?
Yes, Tetrahedron Design Lean factory layout in way that also consider National building codes & Required Safety ISO, We also plan Fire Safety and Fire Exit Doors.
What methods can I use to increase production capacity of manufacturing plant layout design?
By lean plant layout you can increase productivity because lean plant layout decrease machine change over time, waiting of workers, over processing, over production, distance travel by material and manpower and increase overall productivity and also save energy cost .
In how much time will i get Factory plant layout design?
We usually give final Factory plant layout design in 7 to 8 weeks. It also depends upon the size of the plant , Complexity of the production processes, in that case we take 2-3 more weeks.
Can I get help in implementation process on site ?
Yes, after completion of the plant layout tetrahedron will also help in implantation of the suggested layout plan start with machine marking on shop floor to implementation of machine on the floor.
Can I Get multiple 3D simulations of layout according to my requirements ?
Yes, Tetrahedron Create Multiple-3D Possible Layouts with Simulation that enables Clients to take an informed decision considering all future possibilities of Capacity Augmentation, Operational Performance, Manpower Planning, Automation and Digitization. You can also visualize How much inventory is generating in between the processes.
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