In many automation projects, the issue is not the chosen machinery, but how the end-of-line layout has been designed.
A poorly designed layout can:
Limit the system’s real capacity
Create bottlenecks
Make maintenance more difficult
Prevent future expansions
For this reason, when sizing an automated end-of-line, layout design is a critical factor that must be addressed from the beginning of the project.
In the previous article, we discussed how to properly size an automated end-of-line. In this article, we review the most common layout mistakes in automated end-of-lines and how to avoid them.
1. Designing the layout based only on available space
One of the most common mistakes is adapting the end-of-line only to the available space, without rethinking the production flow.
This usually leads to:
Unnecessary product travel paths
Crossing paths between operators and machinery
Poorly located accumulation areas
An efficient layout is not just about “fitting machines in,” but about optimizing product flow from production output to dispatch.
2. Not planning intermediate accumulation zones
An automated end-of-line requires buffer zones, especially when:
There is production variability
There are frequent format changes
Palletizing or wrapping operate at different speeds
A layout without accumulation leads to:
Unnecessary stoppages
Congestion during peak periods
Lower overall efficiency
The layout must include ,regulation spaces,, not just machinery.
3. Underestimating space required for palletizing
Automatic palletizing is one of the processes that most influences layout design.
Common mistakes:
Not considering the robot’s working radius
Placing palletizing in hard-to-access areas
Not allowing space for pallet change or maintenance
A properly sized palletizing system needs space for:
Operation
Safety
Access
Future expansions
4. Designing a rigid layout without room for growth
Another critical mistake is designing the end-of-line only for the current situation, without considering the future.
This may prevent:
Increase throughput
Adding new formats
Incorporating additional shifts
Integrating new machines
A well-designed layout leaves strategic free spaces and allows growth without rebuilding the entire installation.
5. Not integrating safety from the layout design stage
Safety should not be added at the end of the project.
When the layout does not include from the beginning:
Safety fencing
Access zones
Operator flows
Applicable regulations
The result is often:
Wasted space
Forced solutions
Poor ergonomics
A good layout integrates productivity and safety from the design phase.
6. Ignoring maintenance and accessibility
A layout that works well in the first month can become a problem in the medium term if it does not consider:
Maintenance access
Replacement of consumables
Quick interventions
Industrial cleaning
Common mistakes:
Machines placed too close together
Inaccessible critical components
Long downtimes for simple interventions
The layout must facilitate maintenance, not hinder it.
7. Designing the layout without real production data
The most serious mistake: designing the layout without relying on real plant production data.
A correct layout must be based on:
Actual throughput
Production variability
Demand peaks
Format changes
Without this data, the layout becomes a structural limitation of the end-of-line.
The layout is not a static drawing, but the foundation on which the entire automated end-of-line is built.
Avoiding these mistakes allows you to:
Improve real efficiency
Reduce downtime
Facilitate expansions
Maximize return on investment
At IHRESS, layout design is part of the end-of-line sizing process, always based on real production data and a long-term vision.
A good layout not only ensures the line works today, but that it continues to work tomorrow.
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