Abstract
Documenting process flows in a manufacturing environment provides a guide to
understanding how processes are interconnected and how materials are handled, thus
forming the basis for modelling and optimization in order to simplify the otherwise
complex systems particularly in multi-product manufacturing. Research was carried out at
a furniture manufacturing company specializing in the production of a wide range of
furniture from hardwood. Owing to the multiplicity of processes and the movement of
materials in manufacturing environments, the factors affecting such setups increasingly
become complex, equally requiring complex techniques to analyze and optimize them. A
work study carried out at the company established inherent problems that affected
production and were used as the basis for modelling and optimizing the processes, focusing
on grouping of workstations depending on functions, predicting performance using
simulation and machine distance matrices for a reorganized plant layout. Results obtained
after modelling and optimizing the plant layout were useful for production planning and
control as well as enhancing the company’s productivity and efficiency.