Suggested Response - Q5

** List all the elements of an idealised maintenance workshop layout. Describe the purpose of each zone, then highlight the important considerations for each area.

Based on these zone descriptions, provide a sketch of a maintenance workshop layout, incorporating all the elements, and a brief description indicating the rationale behind their locations and relationships to one another.

Response:

A tabular format is recommended to clearly capture all the requested information.  As an example, please see the following:

Maintenance workshop element

Purpose

Physical Aspects

Sanitary/
clean zone

Disassemble, clean, inspect, and rebuild all of the sanitary elements of the brewery, including instrumentation and valves (butterfly, mixproof, pressure relief)
  • Cleanliness is of the utmost importance
  • Located in an isolated section of the shop, free from unnecessary personnel traffic
  • Ideally climate controlled (at minimum filtered room air)
  • Well lit
  • Requires a minimum of hand tools, and a sturdy workbench and vice

Machining/welding/fabricating zone

Repair and fabrication work
  • This work typically generates metal chips, dust, grit, and fumes. 
    • Should be isolated from other work areas, well lit, and ventilated to protect staff and equipment.
  • Tools and equipment include lathes, mills, band saws, drills, and welders.
  • Considerations and accommodations should be made to prevent cross-contamination when working with both carbon steel and stainless steel in this area.  An example is to purchase two like tools, such as a sandblast station.

Spare parts zone

Houses the spare parts inventory, consignment inventory (if applicable), and consumables (fasteners, gaskets, oils/lubricants, sealants)
  • Should include shelving, pallet racks, cabinets, and storage bins to organise and store all the spare parts
  • Restricted access
  • Well organised
  • Accurate spare parts inventory

 

Library/computer access zone

Dedicated space to allow maintenance personnel access to email, work requests, and online vendor information. Houses equipment manuals and service SOPs.  The resident computer has all the pertinent maintenance software (spreadsheets, CMMS, etc.)
  • Clean and quiet
  • Contains a desk with computer, printer, and phone
  • Includes bookshelves to store reference materials

 

Waste/recycling zone

Keep order of brewery waste streams and reduce brewery’s environmental impact
  • Ideally located near machining/welding/fabricating area, as this zone typically generates or handles the majority of brewery waste
  • Dedicated, labelled bins for
    • Metal recycling (copper, stainless steel, carbon steel)
  • Drums for
    • Waste oils to recycle or sell
    • Waste coolant (glycol) or machining fluids

 

We are then asked to provide a maintenance workshop diagram that includes the five main zones – Sanitary/Clean, Machining/Welding/Fabricating, Spare Parts, Library/Computer Access, and Waste/Recycling.

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An ideal layout includes all five of these zones and also:

  • Accommodates the separation of the clean/sanitary zone from the machining/welding/fabrication zone and situates the clean/sanitary zone away from the main thoroughfare

  • Locates the waste/recycling zone near to the machining/welding/fabricating zone, as fabrication typically generates the largest portion of waste and recyclable materials

  • Ensures the library/computer access zone is used as an office or secluded area suitable for research, study, and focused work on maintenance documentation

  • Represents the spare parts zone with walls, fence, or similar to assist in restricting access and ensuring an organised and accurate inventory
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