Process Mapping and Optimization of the Process Flows of a Furniture Manufacturing Company in Zimbabwe Using Machine Distance Matrices

Appropriate arrangement of machinery in a manufacturing environment can have a positive impact on the productivity of a company. A detailed work study carried out at a furniture manufacturing company revealed that parts travelled long distances before the final product is produced owing to the positions of machinery and crisscrossing process flows. This paper looks at how the plant layout was re-organized by mapping process flows and regrouping of the machinery according to their functions and products using machine distance matrices. Challenges relating to the plant layout, process flows, materials handling and transportation as well as assembly procedures were established, coupled with grouping machines according to functions and the least distance between interacting workstations. Using the machine distance matrices, processes were mapped and equipment re-organized to allow for continuous flow of production, resulting in significant reductions in transportation distances among interacting workstations and elimination of crisscrossing process paths.