Assoc. Prof. Songpol Atthakorn
Abstract :
A new factory project for producing inorganic chemical products for agriculture was proposed as an iconic architectural design. The project aims to promote the efficiency of Lean Manufacturing, express the brand identity of the “Blue Wave,” and create a friendly place for workers and visitors. The proposal sets a framework as a design method via the design process. The three conceptual designs were used to transform the three objectives into three building components: enhancing the flow design, creating a sense of movement, and promoting a sense of place. An impressive outcome was expected to get out of the box from the conventional factory.
The results show the design outputs in three main architectural parts: space planning, roof design, and façade design of the factory. Space planning followed the existing structural grid system for adaptive reuse and was used as a common grid for integrating multi-machinery systems. The flow of the production line with direct supporting facilities and close inspection is a major concern. The roof design represents the concept of movement and the expression of the “Blue Wave,” which allows future extension by a modular system. The façade design promotes a friendly place for both workers and visitors by applying human scale and earthtone materials to the base walls. The openness of the front façade allows people to experience natural light and outdoor views. Furthermore, the front signboard tower, fountain pond, and rest areas create a welcoming image for visitors. After the three main architectural components were integrated, the design output of the new factory could express a unique outlook reflecting the project objectives. The results showed that the design process could help produce an output that responds well to the project’s aims. Consequently, the preliminary design was successfully approved by the owner. We hope that this work in progress will help demonstrate how the design framework can effectively generate an aesthetic through synthesis.
Objectives :
The new factory requires the triangular achievements of manufacturing efficiency, marketing identity and a pleasant working environment. The production of basic inorganic chemical products for agriculture requires the integration of multiple mechanical processes within the production line. Continuous and uninterrupted movement of a product through the manufacturing process is required to minimize waste and delay. The factory aimed to comply with the international standards of ISO 9001 and ISO 14001 by promoting the efficiency of Lean Manufacturing (LM), enhancing environmental sustainability, and maintaining an effective Environmental Management System (EMS). The standards require a plan-do-check-act (PDCA) approach for continuous improvement. This causes inspectors and workers to work closer to the production line. The owner also wants to create a brand identity as the “Blue Wave,” which refers to the widespread use of blue copper sulfate throughout the farmland to enhance agricultural fruitfulness. Furthermore, the social interactions and well-being of factory workers are of greater concern. In summary, the objectives of the project are as follows: 1) to promote the efficiency of Lean Manufacturing. 2) to express the brand identity of the “Blue Wave,” and 3) to create a friendly place.
Conceptual Framework :
The conceptual framework demonstrates the design process of the project, including the objectives, design concepts, and design outputs (Figure 2)
Figure 2: Conceptual framework: Design process
Figure 2 shows the three objectives: applying lean manufacturing, expressing the “Blue Wave,” and creating a friendly place. The three objectives were transformed into design outputs by applying three design concepts: enhancing the flow design, creating a sense of movement, and promoting a sense of place. The design outputs are the results of the designs of certain parts of the factory, including space planning, roof design, and façade design.
Process / Methodology :
The design process followed a conceptual framework that was divided into three parts.
7.1 Space planning was designed by using the concept of “flow design.” The main production zone was set in a linear process and was located between the office and the supporting mechanical zones. The first zone of the production line consists of an unloading area, raw material storage, and a preparation area. The second zone is the main production process, which includes alkaline etching, copper oxide, and copper sulfate processes. The third zone is the finished goods storage and loading area. The office, rest area, and parking zone were located in front of the building, whereas the service and supporting mechanical zones were located at the rear of the building. The additional recreation zone and open courtyard were located at the side of the building, which was reserved for future extensions.
7.2 The roof was designed to convey a sense of movement. The main functional roof was divided into two curved roofs, which could be extended to a third curved roof if necessary. The lower roofs of the office and recreation zones had a smaller curve to harmonize the overall look of the complex, whereas the roofs of the other supporting zones were flat and horizontal. The hierarchical forms of the roofs create a sense of movement. All the curved roofs are expressed as a “blue wave” to give a branding identity to the building.
7.3 The façade design was treated to create a sense of place. The design incorporates a human scale, solid and void, earth tone, landmark tower, landscape, and a water feature. The ninety-meter-long front façade has an intermittent rhythm. The size of the entrance, windows, and doors, and the floor height of the two-storey office zone were created according to the human scale to give a sense of friendliness. The solid base façade was finished with an earth-tone brick-like material, while the openness of the façade provided daylight and views of the outside landscape. Furthermore, the front signboard tower with the fountain pond and rest area welcomes visitors.
Techniques and Materials :
The common design technique used in the project was a modular system that integrated multiple building systems, including architectural, mechanical, sanitary, electrical, and transportation systems. All space design and building systems were adjusted to a six-meter grid system. This provides adjustable and expandable spaces to meet optimal requirements. However, each function can independently have its own suitable height and spatial volumes.
Result / Conclusion :
Since the goals of the contemporary factory should not only apply production efficiency and sustainability but should also serve as a brand identity and promote workers’ social interaction and well-being, the design process should respond well to multiple objectives and create clear design outputs. The design framework shows the directions of the design process for each issue.
Following the conceptual framework, the project outlook is the design output. The process generated straightforward answers to the objectives, which were to apply Lean Manufacturing, express the “Blue Wave,” and create a friendly place. The three design concepts used to implement the factory forms were flow design, sense of movement, and sense of place. These could fulfill the creative design for the unconventional look of the factory, which so called the “flow factory and a friendly place.”
References :
Ahmadi, M. (2019). The experience of movement in the built form and space: A framework for movement evaluation in architecture. https://doi.org/10.1080/23311983.2019.1588090
Foote, K.E. & Azaryahu, M. (2009). Sense of place. https://doi.org/10.1016/B978-008044910-4.00998-6
Lin, H. (2023). The application and value of curved roof in modern architecture. https://doi.org/10.54254/2755-2721/12/20230332
VMS consultants. (2023). How to implement Lean Manufacturing principles in facility design? https://www.vmsconsultants.com/how-to-implement-lean-manufacturing-principles-in-facility-design/