Floor Space Utilization: 6 Ways to Maximize Every Inch of Facility Space
Rapid company growth is great for the bottom line, but not always for manufacturer floor space. Unfortunately, it’s fairly common for companies to grow without considering floor space utilization and maximizing facility floor space. The result is a shop that resembles a hoarder’s dream and a sharp drop in efficiency.
Fortunately, there are multiple ways for even the most conscientious manufacturer to maximize floor space---and even find additional square footage available for use.
1. Evaluate existing assets.
2. Revise plant layout.
3. Automate existing processes and movements.
4. Utilize vertical space.
5. Invest in new storage solutions.
6. Narrow aisles.
Evaluate existing assets.
Before any improvements can be made, a full evaluation of assets, including raw materials, machines, and finished products, should be initiated. During the process, facility managers should analyze the list using Lean manufacturing principles and identify items that can be classified as waste. These items should be removed from the plant, if possible. If it is not feasible to remove the items, an effort should be made to consolidate the items into as small of a footprint as possible. For example, scrap metal should be moved to a secure storage space outside, consolidated into efficient vertical storage that occupies minimal square footage, or scheduled for regular pick-up so it does not occupy valuable floor space.
Revise plant layout.
An efficient layout eliminates wasted time and movement by improving material flow. A new layout may involve moving machines so the product is moved efficiently from one process to another, eliminating wasteful excess material handling time. Another element of a new plant layout may include adjustments to storage so bulk items are stored in convenient locations for material flow (and in vertical storage that occupies minimal square footage). It’s important to note that evaluation of a plant layout is an ongoing process that should be reviewed periodically to maintain optimal efficiency.
Automate existing processes and movements.
Automation can be a valuable part of floor space utilization. It can make material handling more efficient, such as using conveyers to move items between machines. An automated machine or machine accessory can also minimize the number of employees needed for a task, which can be invaluable during a labor shortage.
There are many automated solutions for manufacturers, and the right product depends on the operation. There are automated press brake bending cells, automated storage and smart material handling vehicles, and automated accessories for easy material handling.
Utilize vertical space.
Vertical space is a valuable commodity in the effort to maximize floor space, and an often overlooked one. Manufacturers can utilize vertical space for storage, such as with racks that can be installed above overhead doors or large modular storage systems that can be stacked with multiple units. These systems add value while occupying a minimal footprint.
Mezzanines are another way to efficiently use vertical space. These spaces can be built above workspaces, automated cells, or storage areas and can be used for the same functions.
Invest in new storage solutions.
Storage plays an important role in maximizing floor space and can also play a vital part in efficient material handling. In lean manufacturing terms, this is a chance to eliminate wastes, such as time spent looking for items and time spent loading and offloading material.
The right storage also minimizes damage to materials, which creates additional and unnecessary waste (especially when material is priced high or in short supply). Stacks of sheet metal randomly stored around the shop is a glaring example of waste because it increases the risk of damage and time spent looking for material.
If needed, manufacturers should look to customizable module storage systems. These module storage systems can be a valuable asset because they grow with a company. Basically, a company can add onto the initial unit with other modules as additional storage is needed.
Automated storage systems can also be an asset when reducing waste. Horizontal carousels, vertical carousels, and vertical lift modules store items without occupying a lot of square footage and delivers items to the operator. The latter function reduces time spent looking for product.
Narrow aisles.
Another way to maximize facility floor space is to narrow aisles. Aisles can typically be narrowed to approximately 6 feet in material handling areas, though the exact aisle size is different in every manufacturer. Whatever the aisle width, it should be wide enough for optimal material handling practices.
While the floor space utilization process may consume time and incur expense, it is a worthwhile effort because it saves money in the long-term. This is especially true for companies who don’t have to invest in an expansion and/or save money because of faster material handling.