How to make the best layout? What are the points that should be considered?

Introduction

Garment manufacturing industries are following many types of layouts. In that, most of them are not efficient in all aspects. It is having some won merit and demerit. So, how could we make an efficient layout?  What are the basic points that should be considered? We will review one by one in below session.

What is the right layout?

Which layout is suitable to produce better efficiency is called right-layout. Simply arranging manpower, machines, furniture, material, etc. could not be the right layout. We have a few key things which should be considered during the layout design.   

A. Work balance and workmanship distribution    

Thump rule of layout design is workload balancing. Sewing lines is containing many processes. i.e. P1, P2, P3,…., Pn. All the process has to be balanced well. That should not be imbalanced between each and another process. For Example, P1 can produce 120 units, P2 can produce 50 pcs. In these cases, P2 is behind 70 units. This is called an imbalance process in the layout plan.    

 B. Motion and Methods

Motion is a secondary key to consider for layout making. The layout should be focused and designed to reduce unwanted motion in all processes. That may be a motion of machines or the operators. Allowing excess motion is consuming energy and time which is directly liked to cost.     

 C. Process flow (or) Sequence of operations  

Flow process is very important to define the smooth flow. The parts and panels should be move in the line without manual moving. If, the raw materials dropped in starting the process. That should move process by process and get out as a completed product. Creating gaps and break in the flow is leading to waiting and transporting between the processes.  

 D. Transport and moving

In manufacturing line, Moving, and transportation should be reduced. This is increasing the time and energy. Also, it is leading to increasing the throughput time of the product.    

 E. Optimistic Utilization of Resource

Optimistic utilization is the required result at the end. Optimistic in terms of Machine, Man, Workplace, Space, Efficiency, Waste reduction, So on. Overall the layout should be economic type.    

 F. Other Parameters

All the above parameters are considered as a major contributor. Apart from that, we have to consider the below points to make sure our layout is more efficient.   

 1. Operators and skill: Arrange the right operator in the right process. If required, provide advanced skill developing training to match their skill with other operator’s skills. So that line capacity could be even.  

2. Machine and attachment: Arrange a suitable machine with attachments, the machine setting should be suitable to process efficiently. Provide operating training if required, so that machine and man coordination could be improved.    

3. Space and visual control: Space and work area should be comfortable and not so tight or free. The provided workplace should be suitable to reduce handling time with better ergonomics. Sometimes a messy look layout is leading a lack of visual control. A good layout could see the identification of process, part, and critical process.

4. Less change over and flexible: Setup the flexible type of layout for easy changeover.

5. Comfort coordination: Layout should be suitable for better coordination of Man: Machine: Process performing.

6. Workshop and product safety: Check and ensure workplace safety for man and product.  

7. WIP and waste control from source: Suitable place should be there to maintain the required Work in Progress. Providing more or less work may lead to imbalanced WIP.  

8. Identification of process and abnormal: The layout should specified the name of the process, parts, assemble point, checkpoint, critical process, traffic light sytem, so on.  

  F. Conclusion

Before start preparing the layout. The manufacturing methods and flow process should be finalized. which is considered all parameters of work balanced, motion, transporting, and optimal utilization. The designing layout is not a one-time job. we have to kee observe the better opportunity for continual improvement and achieve better efficiency.