Abstract
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.