Impact of Facility Layout and Workflow Optimization on Production Efficiency

In today’s manufacturing settings, inefficiencies relating to the layout of manufacturing facilities and inefficient work processes are significant factors in rising operational costs, longer production lead times and less efficiency. This research examines the effect of layout planning of facilities and flow optimization on production efficiency by focusing on three manufacturing settings, which include global, African, West African and Nigerian manufacturing. The main goal is to investigate the aspects of systematic layout designs or optimized workflows that optimize material handling, labor productivity, throughput, and resource utilization that can resolve bottlenecks and inefficiencies in the operation. Guided by conceptual research approach, the research uses a systematic examination of secondary sources of data (i.e., peer-reviewed journal articles, books, industry reports, historical information) to synthesize understanding of facility layout and workflow management. The analysis shows that by integrating the application of layout optimization approaches (e.g. SLP, ALDEP) and workflow optimization (lean tools, simulation, AI and AR/VR) offers measurable improvement of efficiency in production, cost reduction and sustainable operating performance. Key challenges identified include low adoption of technology in use, resource challenges and implementation barriers in developing economies. The study suggests that manufacturing managers and policymakers adopt digital tools, simulation software, and best practices in facility and workflow design to achieve facility operational excellence. Ultimately, the paper underscores the importance of the strategic layout and the management of workflow in driving manufacturing systems productivity, competitiveness and sustainability.