04Layout & infrastructure
Design the flow first, then the building.
Zone the factory around material movement and size utilities against the process — with room to grow.
Zones
Fifteen functional zones.
Z01
Receiving
Controlled entry point for incoming material and vehicles.
Z02
Raw Material Stores
Identified, segregated storage for incoming stock.
Z03
Incoming Inspection
Verification of material before it enters production.
Z04
Production
Core process area arranged along the material flow.
Z05
WIP Storage
Buffer for part-finished material between operations.
Z06
Assembly
Joining and build-up of components into products.
Z07
Quality & Testing
Inspection and test placed close to the process.
Z08
Finished Goods
Separated storage for released, saleable output.
Z09
Packaging & Dispatch
Protection, documentation and outbound loading.
Z10
Tool Room
Tooling, fixtures and their control and upkeep.
Z11
Maintenance
Spares, workshop and planned machine attention.
Z12
Utilities
Power, air, water and services distribution.
Z13
Waste Handling
Segregated collection and controlled disposal.
Z14
Office / Welfare
Administration and worker welfare facilities.
Z15
Emergency Access
Clear routes, exits and emergency equipment access.
Layout principles
- Design material flow first
- Separate raw material, WIP and finished goods
- Avoid backtracking
- Place inspection near the process
- Provide machine maintenance access
- Separate pedestrians and vehicles
- Segregate hazardous operations
- Plan expansion space
- Keep maintenance and tooling accessible
Utilities
Questions to answer early.
Power
What connected load, voltage, backup and power-quality controls are needed?
- Connected load
- Voltage and supply type
- Backup arrangement
- Power quality
Water
What quantity, quality and treatment does the process and facility need?
- Process water
- Utility water
- Treatment
- Storage
Compressed Air & Gases
What pressure, flow, dryness and distribution are required?
- Pressure and flow
- Air quality
- Gas storage
- Distribution
HVAC & Environment
What temperature, humidity, cleanliness and ventilation does the process demand?
- Temperature
- Humidity
- Cleanliness
- Ventilation and extraction
Foundations & Lifting
What floor loading, foundations and material movement capacity are needed?
- Floor loading
- Machine foundations
- Cranes and hoists
- Access routes
Waste & Drainage
Which waste streams are generated and how are they segregated and handled?
- Waste streams
- Segregation
- Drainage
- Disposal route
Logistics
How do vehicles, material and people move on site without conflict?
- Vehicle access
- Docks
- Internal movement
- Pedestrian separation
Expansion
Where will additional capacity, utilities and storage physically go?
- Spare floor space
- Utility headroom
- Storage growth
- Layout flexibility