How to Cite it
Johnbull, E. U., Osuchukwu, N. C., & Omoniyi, A. E. (2026). Comparative Evaluation of Facility Layout Design Methodologies: Implications for Organizational Performance. International Journal of Research, 13(1), 213–218. https://doi.org/10.26643/ijr/2026/2
Egbukichi, Ugonna Johnbull1
Department of Industrial Safety and Bio-Environmental Engineering Technology. Federal College of land Resources Technology Owerri, Imo State
Omuma.jupoceada@gmail.com
Nkechi Cynthia Osuchukwu (Ph.D)2
Department of Political Science,
Chukwuemeka Odumegwu Ojukwu University, Igbariam,
Anambra State, Nigeria
Awe Emmanuel Omoniyi3
Department of Economics
Nile university of Nigeria
Email – emmanuel.awe@nileuniversity.edu.ng
Abstract
This study examines eight facility layouts and designs methodologies, including Systematic Layout Planning, Activity Relationship Chart, Space Relationship Diagram, Graph Theory, Simulation Modeling, Lean Layout Design, Sustainable Design and computer aided design. The results highlight the complexities of facility layout design and the importance of selecting the most suitable methodology based on organizational goals and objectives. The study concludes that effective facility layout design can significantly enhance organizational efficiency, minimize waste, and promote sustainability.
Keywords: Facility layout design, Methodologies, Systematic Layout Planning, Activity Relationship Chart, Graph Theory, Simulation Modeling, Lean Layout Design, Sustainable Design, computer aided design.
1.0 Introduction
Facility layout and design refer to the strategic arrangement of physical resources, such as machinery, equipment, and workstations, within a production or service facility (Heragu, 2016). The primary goal is to create an efficient, safe, and productive work environment that supports the organization’s overall objectives (Tompkins et al., 2010). In highly competitive environments, effective facility layout plays a critical role in enhancing customer experience, improving workflow efficiency, and supporting employee responsiveness, all of which contribute to customer satisfaction and sustained patronage
1.1 Aims
The aims of facility layout and design include:
1. Improved Efficiency: Minimize distances, reduce transportation costs, and streamline workflows.
2. Increased Productivity: Optimize workspace utilization, reduce congestion, and enhance employee comfort.
3. Enhanced Safety: Identify and mitigate potential hazards, ensure compliance with safety regulations, and provide a healthy work environment.
4. Better Customer Experience: Design facilities that are welcoming, easy to navigate, and provide excellent service.
5. Cost Reduction: Minimize waste, reduce energy consumption, and optimize resource utilization.
1.2 Objectives
The objectives of facility layout and design include:
1. Maximize Space Utilization: Optimize the use of available space to accommodate equipment, workstations, and personnel.
2. Minimize Material Handling: Reduce the distance and effort required to move materials, products, and equipment.
3. Improve Workflow: Streamline processes, reduce congestion, and enhance communication among departments.
4. Enhance Flexibility: Design facilities that can adapt to changing production requirements, new technologies, and evolving customer needs.
5. Ensure Compliance: Meet regulatory requirements, industry standards, and organizational policies.
2.0 Literature review
Facility layout and design is a critical aspect of industrial production systems, as it directly impacts productivity, efficiency, and safety (Heragu, 2008). Effective facility layout planning involves arranging elements that shape industrial production, including the arrangement of machines, workstations, and storage facilities (Tomkins et al., 2010).
2.1 Key Components of Facility Layout Planning:
– Design Layout: The physical arrangement of facilities, including the location of machines, workstations, and storage facilities (Meller & Gau, 1996).
– Accommodation of People: Ensuring that the facility layout accommodates the needs of employees, including safety, comfort, and accessibility (Das & Heragu, 2006).
– Processes and Activities: Designing the facility layout to support efficient workflows and processes (Benjaafar et al., 2002).
Facility Layout Design Considerations:
– Plant location and design (Kumar et al., 2017)
– Structural design (Smith & Riera, 2015)
– Layout design (Drira et al., 2007)
– Handling systems design (Heragu, 2008)
– Risk assessment and mitigation (Taticchi et al., 2015)
2.2 Space Utilization: The layout should maximize the use of available space while minimizing waste (Drira et al., 2007).
2.3 Material Flow: The layout should facilitate efficient material flow, reducing transportation costs and improving productivity (Heragu, 2008).
2.4 Employee Safety: The layout should ensure employee safety, providing adequate space for movement and reducing the risk of accidents (Das & Heragu, 2006).
Effective facility layout planning can improve productivity, reduce costs, and enhance safety (Heragu, 2008). A well-designed facility layout can also improve communication, reduce errors, and increase employee satisfaction (Das & Heragu, 2006).
3.0 Methodologies and Tools
3.1 Systematic Layout Planning (SLP)
SLP is a structured approach to facility layout design, focusing on the relationship between departments and the flow of materials (Muther, 1973). This methodology involves analyzing the organization’s goals, products, and processes to create an optimal layout.
3.2 Activity Relationship Chart (ARC)
ARC is a graphical method used to analyze the relationships between different activities or departments within a facility (Muther, 1973). This chart helps designers identify the most important relationships and create a layout that supports efficient workflows.
3.3 Space Relationship Diagram (SRD)
SRD is a visual tool used to represent the relationships between different spaces or areas within a facility (Liggett, 2000). This diagram helps designers understand how different spaces interact and create a layout that supports the organization’s goals.
3.4 Graph Theory
Graph theory is a mathematical approach used to optimize facility layouts by representing the relationships between different nodes or departments (Tompkins et al., 2010). This methodology helps designers create layouts that minimize distances and maximize efficiency.
3.5 Simulation modeling: Employ simulation software like Simio, Arena, or Witness to analyze and optimize facility layouts (Egbunike, 2017).
3.6 Lean principles: Apply lean methodologies to eliminate waste, reduce variability, and improve flow (Badiru, 2009).
3.7 Sustainable Design: Sustainable design is an approach that focuses on creating facility layouts that minimize environmental impact and support sustainability (USGBC, 2013). This methodology involves analyzing the organization’s sustainability goals and creating a layout that supports energy efficiency, water conservation, and waste reduction.
3.8 Computer-Aided Design (CAD): A software tool used to create and modify facility layouts, improving accuracy and reducing design time (Tomkins et al., 2010).
4.0 Results
The study examined eight facility layouts and designs methodologies, including Systematic Layout Planning (SLP), Activity Relationship Chart (ARC), Space Relationship Diagram (SRD), Graph Theory, Simulation Modeling, Lean Layout Design, Sustainable Design and Computer Aided Design (CAD).
Each methodology has its unique approach and benefits, ranging from optimizing material flow and minimizing distances to eliminating waste and supporting sustainability.
4.1 Discussion
The results show that facility layout design is a complex task that requires careful consideration of various factors, including organizational goals, product and process requirements, and sustainability objectives. The choice of methodology depends on the specific needs and goals of the organization. For instance, SLP and ARC are suitable for analyzing relationships between departments and activities, while Graph Theory and Simulation Modeling are more effective for optimizing material flow and minimizing distances. Lean Layout Design and Sustainable Design are essential for organizations that prioritize waste elimination and environmental sustainability.
5.0 Conclusion
In conclusion, facility layout design is a critical aspect of organizational efficiency and effectiveness. The Eight methodologies examined in this study offer valuable approaches for designing and optimizing facility layouts. By selecting the most suitable methodology based on their specific needs and goals, organizations can create facility layouts that support efficient workflows, minimize waste, and promote sustainability. Future research should focus on exploring the application of these methodologies in different industries and contexts, as well as developing new methodologies that address emerging trends and challenges in facility layout design.
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