Customizable facility
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Solution Overview
Problem
Traditional manufacturing facilities are inefficient in utilizing space and cannot be easily configured or expanded to accommodate new product lines, leading to limitations in manufacturing multiple products efficiently and reducing facility downtime.
Innovation Solution
A customizable facility design featuring a shell with central and modular units, allowing for flexible arrangement and expansion to maximize manufacturing capacity, with modular units such as fermentation, pre-viral, and post-viral units, and utilities, enabling efficient resource sharing and adaptation to different product lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional manufacturing facility structures are used, then the facility layout is fixed and stable, but the facility cannot be easily configured or expanded to accommodate new product lines
Solution Approach 1:
The facility is divided into modular units that can be independently configured and arranged. Each module contains specific manufacturing equipment and can be repositioned or reconfigured to accommodate different product lines, enabling flexible facility adaptation without complete restructuring.
Solution Approach 2:
The modular units are designed with universal interfaces and standardized configurations that allow them to serve multiple manufacturing functions. The same modular structure can accommodate different product lines by changing the internal equipment arrangement rather than requiring dedicated facilities for each product.
2Area of stationary object
If traditional facility layouts are used, then the structure is stable and established, but space utilization is inefficient and expansion is difficult
Solution Approach 1:
The facility layout transitions from a static traditional design to a dynamic modular configuration where units can be moved, added, or removed based on production needs. This dynamic arrangement optimizes space utilization while maintaining expansion capability through standardized modular interfaces.
3Ease of manufacture
If fixed facility configurations are used, then construction is straightforward, but facility modification requires significant downtime and resources
Solution Approach 1:
Modular units are pre-configured and pre-tested outside the main facility before being installed. This preliminary preparation allows for rapid deployment and minimizes the time required for facility modifications, as units can be swapped out without extensive on-site construction or downtime.
Data Source
AI summary
A customizable facility for manufacturing at least one product has at least one modular unit in communication with at least one central unit configured to provide utilities to the at least one modular unit. In some embodiments, the central unit(s) and modular unit(s) are positioned at least partially within a shell. Each modular unit can be a fermentation unit, a pre-viral unit, a post-viral unit, a utility space, a warehouse, a media buffer facility, an office, a personnel unit, or another unit. The modular units can be arranged to maximize a number of modular units within the shell while minimizing a footprint of the shell. A method of assembling a facility for manufacturing at least one product includes providing at least one central unit and providing at least one modular unit in communication with the central unit(s) such that utilities are provided by the central unit(s) to the modular unit(s).