Dynamic Site Layout Optimization Using Worker Movement Tracking
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Solution Overview
Problem
Existing site layout planning methods rely on static data, failing to account for actual worker movements and resulting in suboptimal safety and productivity due to the inability to distinguish between safe and unsafe zones, especially in dynamic factory environments where additional areas are added without considering worker productivity and safety.
Innovation Solution
A method and system that tracks inter-zone movements of workers, classifies these movements into primary, secondary, and tertiary categories, and generates an optimized layout plan based on these movements and existing layout parameters to improve safety and productivity by determining dependencies between movements and existing layout parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If static data is used for site layout planning, then the layout can be initially established with predefined inter-zone movement, but it fails to account for actual worker movements and deviations from anticipated movement patterns
Solution Approach 1:
The patent transitions from static layout planning to dynamic layout optimization by continuously tracking worker movements using IoT devices and adjusting the layout based on actual movement patterns. The system monitors real-time location data, categorizes movements into primary/secondary/tertiary types, and dynamically reconfigures zone arrangements to match observed workflows, thereby improving both safety and productivity while maintaining layout adaptability.
2Area of stationary object
If additional blocks or areas are added to expand the site, then the facility capacity increases, but worker productivity and safety aspects are not considered with a holistic layout approach
Solution Approach 1:
The system implements continuous feedback loops where worker movement data from expanded areas is collected via IoT trackers, analyzed to identify movement patterns and inefficiencies, and used to iteratively optimize the layout. This feedback mechanism ensures that as the facility expands, the layout continuously adapts to maintain or improve productivity by repositioning zones based on actual worker behavior rather than static assumptions.
3Device complexity
If static layout parameters are used, then the layout design is simplified, but it cannot distinguish between safe and unsafe zones or account for unexpected worker movements
Solution Approach 1:
The patent segments the site into multiple zones with distinct safety characteristics and monitors worker transitions between these zones. By dividing the facility into discrete monitored areas and tracking inter-zone movements, the system can identify unsafe movement patterns, detect workers entering hazardous areas, and provide targeted safety alerts, thereby reducing accident risk while maintaining manageable design complexity through systematic zone classification.
Data Source
AI summary
Present invention discloses method and system for providing an optimized layout plan for a site. Method comprising tracking inter-zone movement of at least one person operating in one or more zones at the site, generating inter-zone movement sequence from the inter-zone movement and classifying the inter-zone movement sequence into at least one of primary movement, secondary movement and tertiary movement. Thereafter, method comprising determining a dependency of the primary movement on the secondary movement of the at least one person while executing a primary task by the at least one person and generating the optimized layout plan for the site based on at least one of the primary movement, the secondary movement, the tertiary movement of the at least one person, the dependency of the primary movement on the secondary movement of the at least one person and existing layout parameters of the site.