How to design a good layout?
Explaining a layout design process in writing, when its final result is graphic in nature and dependent on various factors, is a complex task. However, we will answer common questions raised by companies, through experience in the field of logistics consulting and the design of world-class distribution centers in Mexico, Latin America, Europe and Asia.
What is layout design?
It consists of the integration of the different functional areas (which make up the solution of a logistics facility) in a single building. It covers not only the arrangement and composition of the functional sections internal to that building (what lies within the four walls), but also the other external areas. The latter is also distinguished as masterplan design. These approaches differ if the layout is to be designed from an existing building or not, if a building already exists, if the space heights are restricted, if the building access is already constructed, if there are buildings that can not be relocated And a long list of conditions.
What is recommended before starting?
It is best to reflect and find a method that simplifies and sustains the final solution, as well as trim the tree of possible alternatives in a logical and structured way. For this, you should gather as much information as possible. Take some time before you start with calculations, tables and CAD. Reflect on what steps you will take to design your layout.
What are the main areas to consider in layout design?
Reception and dispatch zones, storage, order picking, quality control and inspection, maneuvering yards and parking lots, among others. However, to make a complete layout design it is necessary to make an exhaustive list of these and other areas that make the functionality of the solution, such as maintenance area, battery charging, sanitary ware, dressing rooms, offices (control, Administrative, surveillance, booths), assembly of offers or maquilas and transfers.
What does it take to start a design like this?
The list above should include not only the dimensioning of each area (how much surface area and height), the processes and their schedules, but also the equipment that will be required in each case: 1) Type of cargo units to be handled (Pallets, drums, boxes, coils, etc.); 2) type of shelving and modulation (selective, double depth, drive-in, push-back); 3) type of vehicles (pallet trucks, forklifts, reach-trucks); 4) number of staff; 5) environmental conditions; 6) lighting level; 7) services and supplies; 8) security features, and 9) others, depending on the destination.
What is important to rank?
Ls functional relationships (importance, frequency, safety), flows of materials and processes, within and between said areas, to determine their physical proximity or distance, through flow charts or functional matrices.
What are the most relevant criteria for layout design?
Finding possible synergies of use between different areas will allow us to reduce surfaces: perhaps some areas are used only for a few hours in the day, being available for other activities, for example, platforms of simultaneous receipt and expedition.
What should be the most important areas?
They should be as regular, symmetrical as possible and try to maintain a rectangular perimeter. This facilitates the visualization of the installation for both management and operation. In each case the suitability of accessing them by the minor or major sides will be analyzed. Coordinate the structure of the building (floors, columns) and its facilities (existing or proposed) with the functional areas, so that some are multiples of others, facilitating solution flexibility (relocation, future growth).
What is more important, a few extra inches in the aisles or some more pallets to store?
In general, prioritize the circulation space versus the storage space, when it is necessary to adjust aisles or maneuvering areas (it is preferable to gain centimeters to a corridor than to the shelves). Many times what is gained in storage is lost due to the slow operation, damages to equipment, shelves and accidents. In addition, it is more difficult to find precision surgeons among the truckers.
How do I plan?
Plan the steps and the directions of circulation between areas avoiding bottlenecks or conflicting crossings where high or very frequent flows are envisaged. Consider the effect of shift change. Remember that on the floors circulate vehicles and people, pr