Optimization of a plant layout and materials handling system for a furniture manufacturing company

The proper layout and efficient utilization of resources; human, machinery and space can have a positive bearing on the productivity of manufacturing companies. A case study was carried out at a furniture manufacturing plant in Harare, Zimbabwe and this paper presents the findings and proposals for an optimized plant layout and materials handling system. Inherent problems within the manufacturing setup were identified through the use of questionnaires and the company's available documentation. These ranged from crisscrossing process flows, undocumented production plans and inadequately planned materials processing and handling. Following a detailed work study, production planning and control techniques for materials handling, processing and assembly were introduced to improve production throughput times. Three alternative models were conceptualized and the best model was selected using the payback period method while optimization of the plant was achieved through a novel approach of process mapping of the layout, available space and materials handling machinery. Results obtained from the assessment of the selected model revealed that transportation distances can be reduced significantly while production throughput time decreases.