Redesign and control of backtracking of process paths in manufacturing plant layouts for productivity and sustainability

The layout of workstations, sequence and flow of parts in a manufacturing environment have significant bearings on productivity and efficiency of manufacturing companies. Research carried out at a furniture manufacturing company in Zimbabwe revealed that parts and sub-assemblies in the plant traversed long distances during processing, exhibiting crisscrossing and backtracking of process flows. Coupled with the other challenges such as failure to provide timely product deliveries to meet customer demands, the research focused on redesigning the layout of workstations using simulation and group technology for prediction of performance, identification of bottlenecks and efficient utilization of space and resources. This was aimed at controlling the backtracking of process paths by reducing travel distances and lead times. The reorganized plant achieved an average 26.5% reduction in manufacturing lead times and 48% reduction in travel distances, which translated to improvements in productivity for the sustainable and competitive manufacture of furniture for the domestic and commercial market.