Abstract
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.