A Review Article On: An Approach Towards Plant Layout

The design of a pharmaceutical plant layout is a critical aspect of constructing facilities for the production of medicines and related products. A well-planned layout guarantees safe, efficient, and compliant pharmaceutical manufacturing, while also meeting regulatory requirements and managing costs. It is carefully structured to improve workflow, reduce contamination risks, ensure the safety of personnel, and uphold product quality. (1)

Plant Location

The decision regarding the optimal location for a plant or factory is a crucial one for every entrepreneur. Plant location refers to the process of selecting both the region and the specific site for establishing a business or manufacturing facility. This decision is typically made after carefully considering the costs and advantages of various potential sites. It is a strategic choice that is often irreversible and, if changed, could incur significant losses. The location should be chosen based on its alignment with the business's specific requirements and circumstances. Each plant location is unique and should be evaluated individually. Entrepreneurs should strive to identify the most optimal or ideal location for their business. An ideal location is one that minimizes the cost of production while maximizing market share, reducing risk, and providing the highest possible social benefit. It is the location that offers the greatest net advantage, or the one that results in the lowest unit costs for both production and distribution. To achieve these goals, small-scale entrepreneurs can employ location analysis as a tool to assist in selecting the best site for their business. (2)

Selection Criteria

The key factors to consider when selecting an appropriate location for a business are as follows:

a) Natural and Climatic Conditions: The environmental and weather conditions of the area must be suitable for the business operations.

b) Proximity to Raw Material Sources: The location should be close to the sources of raw materials to minimize transportation costs and ensure a steady supply.

c) Transport Costs: This includes the cost of transporting raw materials to the plant and the distribution of finished products to the end consumers.

d) Market Accessibility: For small businesses, particularly in retail, wholesale, or services, being located in densely populated areas is crucial for ensuring easy access to a large customer base.

e) Availability of Infrastructure: Essential infrastructure such as industrial sites or sheds, access to roads, proximity to railway stations, airports, or seaports, along with reliable utilities like electricity, water, and communication services, is vital, particularly for small-scale enterprises.

f) Labor Availability: The site should offer access to both skilled and unskilled labor, as well as qualified and trained managerial staff to efficiently run the business.

g) Location Connectivity: Locations that are connected to industrial hubs or business districts can lead to cost savings and reduced overheads, particularly in terms of transportation and other logistical expenses.

h) Safety and Security: The safety and security of the location should be a top consideration to ensure the protection of both assets and personnel.

Plant Layout

The efficiency of production is largely determined by the optimal placement of machines, production facilities, and employee amenities within a plant. A well-designed plant layout ensures the smooth and efficient movement of materials, from the raw material stage to the final product. Plant layout includes both new designs and improvements to existing layouts. It can be defined as the process of strategically positioning machines, processes, and plant services within the factory to achieve the desired quantity and quality of output while minimizing manufacturing costs. This involves a thoughtful arrangement of production facilities to ensure a streamlined workflow. Plant layout refers to the organization of physical resources, such as machinery, equipment, and furniture, within the factory space to ensure the quickest and most cost-effective flow of materials. It aims to minimize handling during the product processing journey, from material receipt to the shipment of finished goods. As Riggs states, the primary objective of plant layout is to design a physical setup that most economically fulfills the required output—both in terms of quantity and quality. Similarly, J.L. Zundi defines plant layout as the process of allocating space and arranging equipment in a way that minimizes overall operating costs. (3)

Objectives Of Plant Layout

? Maximized Utilization of Equipment and Workforce: Ensuring efficient use of machinery and human resources.

? Minimized Material Movement: Reducing unnecessary material transportation to save time and resources.

? Elimination of Production Bottlenecks via Line Optimization: Streamlining production lines to avoid delays and inefficiencies.

? Reduction of Physical Effort with Cost-Effective Automation: Using automation solutions that minimize manual labor at a low cost.

? Increased Production Output and Decreased Delivery Failures: Achieving higher throughput while minimizing the risk of delays in delivery.

? Lowering Work-in-Progress (WIP) Inventory between Operations: Reducing intermediate stock between processes to improve efficiency.

? Optimized Lighting, Ventilation, and Noise Control for Better Work Conditions: Creating a comfortable and energy-efficient working environment.

? Adequate Workspace for Enhanced Operational Conditions: Providing sufficient space to ensure smooth and safe operations.

? Effective Aisle and Gangway Layouts for Easy Access and Monitoring: Organizing paths for easier movement and supervision of the floor.

? Strategic Warehouse Design for Improved Flow and Material Management: Organizing storage based on flow optimization, capacity, and ease of material tracking.

? Decreased Setup Time with SMED (Single-Minute Exchange of Dies): Reducing the time needed to switch over between production runs.

? Dust and Cleanliness Control Based on Cleanroom Standards and ISO Guidelines: Maintaining cleanliness to meet industry standards and improve air quality.

? Shortened Travel Distances for Materials and Workers: Minimizing unnecessary movement of both materials and personnel.

? Lower Labor Expenses: Reducing the cost associated with workforce management and operation.

? Faster Manufacturing Process: Cutting down production time through optimized layout and processes.

? Enhanced Operational Flexibility: Enabling adjustments to production lines to accommodate changing demands.

? Room for Future Expansion: Designing the plant layout to allow for future growth and scalability. (4)

Importance Of Plant Layout

An effective plant layout creates a harmonious interaction between raw materials, production processes, space utilization, and final output. It maximizes the use of available space while allowing for adaptable setups and manufacturing activities. A well-planned layout facilitates smooth inventory flow throughout the facility, minimizing delays or disruptions. It also helps maintain efficient material movement, cuts down lead times, reduces handling costs, and promotes a safe, comfortable, and user-friendly environment for workers. (5)

Plant Layout Challenges

•Challenge 1: Material Flow

•Challenge 2: Space Utilization

•Challenge 3: Equipment Layout

•Challenge 4: Worker Safety

•Challenge 5: Environmental Impact

•Challenge 6: Industry Specificity

•Challenge 1: Material Flow

One of the main challenges of plant layout is to ensure a smooth and uninterrupted flow of materials from the raw materials to the finished products. Material flow affects the production time, cost, waste, and inventory levels. A poor material flow can cause bottlenecks, delays, congestion, and errors. To solve this challenge, you need to map the current material flow and identify the sources of inefficiency and waste. Then, you need to apply the principles of lean manufacturing, such as reducing the distance, eliminating the non-value-added activities, and minimizing the handling and transportation. You can also use tools such as value stream mapping, spaghetti diagrams, and material flow analysis to visualize and improve the material flow.

•Challenge 2: Space Utilization

Another challenge of plant layout is to utilize the available space in the most effective and efficient way. Space utilization affects the capacity, flexibility, and safety of the plant. A poor space utilization can result in underutilization, overcrowding, or waste of space. To solve this challenge, you need to measure the current space utilization and compare it with the industry benchmarks and best practices. Then, you need to apply the principles of ergonomics, such as optimizing the layout, reducing the motion, and improving the comfort and convenience. You can also use tools such as CAD software, simulation models, and layout optimization algorithms to design and evaluate different space utilization scenarios.

•Challenge 3: Equipment Layout

A third challenge of plant layout is to arrange the equipment in a way that maximizes the performance, reliability, and maintainability of the machines. Equipment layout affects the quality, productivity, and availability of the plant. A poor equipment layout can cause breakdowns, defects, or downtime. To solve this challenge, you need to assess the current equipment layout and identify the potential problems and risks. Then, you need to apply the principles of reliability engineering, such as selecting the appropriate equipment, ensuring the compatibility and integration, and implementing the preventive and predictive maintenance. You can also use tools such as reliability block diagrams, failure mode and effects analysis, and fault tree analysis to analyze and improve the equipment layout.

•Challenge 4: Worker Safety

A fourth challenge of plant layout is to ensure the safety and health of the workers who operate and maintain the plant. Worker safety affects the morale, motivation, and retention of the workforce. A poor worker safety can cause accidents, injuries, or illnesses. To solve this challenge, you need to review the current worker safety and identify the hazards and exposures. Then, you need to apply the principles of occupational safety and health, such as eliminating or minimizing the hazards, providing the personal protective equipment, and training and educating the workers. You can also use tools such as safety audits, risk assessments, and safety management systems to monitor and improve the worker safety.

•Challenge 5: Environmental Impact

A fifth challenge of plant layout is to minimize the environmental impact of the plant operations. Environmental impact affects the compliance, reputation, and sustainability of the plant. A poor environmental impact can cause pollution, emissions, or waste. To solve this challenge, you need to measure the current environmental impact and compare it with the regulatory and voluntary standards. Then, you need to apply the principles of environmental engineering, such as reducing the energy and water consumption, recycling and reusing the materials, and treating and disposing the waste. You can also use tools such as life cycle assessment, environmental impact assessment, and environmental management systems to evaluate and improve the environmental impact.

•Challenge 6: Industry Specificity

A sixth challenge of plant layout is to adapt to the specific requirements and characteristics of the industry. Industry specificity affects the competitiveness, innovation, and differentiation of the plant. A poor industry specificity can cause loss of market share, customer dissatisfaction, or obsolescence. To solve this challenge, you need to research the current industry trends and best practices and benchmark your plant performance and layout with the industry leaders and competitors. Then, you need to apply the principles of strategic management, such as aligning the plant layout with the business goals, meeting the customer needs and expectations, and creating the competitive advantage. You can also use tools such as SWOT analysis, competitive analysis, and balanced scorecard to plan and implement the industry-specific plant layout strategies. (6)

Types Of Plant Layout

1. Line or Product Layout

In a product or line layout, machines and equipment are organized in a linear sequence according to the specific operations required for the product. The materials flow from one workstation to the next in a continuous, sequential manner, with no backtracking or detours. This layout involves arranging machines in a fixed sequence, so that materials are fed into the first machine, and the output of one machine automatically serves as the input for the next. A prime example of this system is seen in industries such as paper mills, where goods move progressively through the production process.

1. Process Layout

In a process or functional layout, machines of similar types are grouped together in designated areas based on the specific operations they perform. For example, machines that carry out drilling operations are placed in the drilling department, while those for casting are organized in the casting department. This layout organizes plants according to specialized departments, such as drilling, milling, welding, heating, and painting departments. The process layout has its origins in the historical handicraft method of production. In this layout, work is allocated to departments in such a way that machines are not specialized for a single task but are instead designed for versatile, general-purpose use. The focus is on maximizing the utility of each machine for a variety of tasks, rather than limiting them to one specific operation.

2.  Location Layout or Fixed Position

In a fixed-position layout, the primary product being manufactured remains stationary at a single location. All necessary equipment, labor, and components are brought to this location to perform various operations. The facilities and resources are arranged around the work center to support the production process. This layout is typically used for large, complex products that cannot be easily moved, such as ships, airplanes, or large construction projects. However, this type of layout is generally not suitable for small-scale enterprises due to the significant space, resources, and coordination required.

3.  Group or Combined Layout

Some manufacturing units may require a combination of different processes, such as intermittent processes (job shops), continuous processes (mass production shops), and representative processes (miscellaneous shops). In most industries, a single layout type—whether product, process, or fixed-position—is not typically used in isolation. Instead, many manufacturing concerns adopt a combined layout, especially when several products are produced in repeated quantities without the need for continuous production. A typical approach is the combination of product and process layouts, or other hybrid configurations, depending on the nature of the production. For example, in industries involving part fabrication and assembly, fabrication often follows a process layout, while assembly areas typically employ a product layout. In a soap manufacturing plant, the production machinery for soap is arranged according to a product line layout, but auxiliary services such as heating, glycerin production, the power house, and water treatment facilities are organized based on a functional layout. (7)

Development of integrated process layout for the production of various type of formulation:  for development of process flow diagram initially identified the operation and their sequence so methodology used for development of industrial process layout involve following steps:

a) Selection of formulation for which integrated layout to be developed

b) Study of basic operation and their sequence involve in manufacturing process of formulation

c) Identification and separation of operation/steps into common and different on basis of process

Description

A

Selection of Formulations for Integrated Layout Development
In this step, a variety of formulations have been identified for the purpose of developing an integrated process layout. These include traditional pharmaceutical dosage forms such as tablets and injections, cosmetic products like lipsticks and face powders, as well as advanced drug delivery systems including microspheres and liposomes.

B

Analysis of Manufacturing Steps for Selected Formulations in a Schematic Format
To facilitate the development of an integrated process flow layout, a clear and simplified schematic representation of the manufacturing steps has been created. This approach helps streamline the sequence of operations and minimizes confusion that may arise from varying sources of information.

C

Classification of Process Steps into Primary and Secondary Categories
Through detailed observation of the step-by-step procedures involved in the production of different pharmaceutical dosage forms, the individual operations have been categorized into primary and secondary steps based on their role and importance within the overall manufacturing process. (8)

List of formulation selected for the development of process layout design for production:

1-Powder

2-Suppositories

3-Emulsion

4-Suspension

5-Tablet

6-Tapsule

7-Lotion

8-Creams

9-Syrup

10-Lipstick

11-Shampo

1 -Powder

Mixing

Homogenization

Packaging

Labeling

Storage

2 -Suppositories

Lubrication

Filling in Molds

Scratching

3 -Emulsion

Trituration

 4-Syrup

Heating

 5-Tablet

1.Uncoated tablet

Sieving

Drying

Punching

De dusting

2.Coated tablet

Coating

Drying

Polishing

6 - Parenteral

Filtration

Sterilization

Buffering

Checking for leak test

7- Microsphere

Dispersion

Centrifugation

Washing

Drying

8 -Lipsticks

Grinding

Molding

Heating

Packing

9 -shampoo

Heating

Product Flow Diagram:

Parenteral Dosage Form