ENHANCING FACILITY LAYOUT PLANNING (FLP) EFFICIENCY THROUGH SIMULATION

Abstract

Facility layout planning (FLP) which involves organizing production process components within a physical space, presents unique design challenges. This study addressed inefficient FLP at Workshop S, an automobile repair workshop, due to poor space utilization and reduced operational efficiency. This study also proposed an optimum layout to improve operation time and cost-efficiency. Conducted in Pekan Pagoh, Johor, this study employed a combination of layout design and simulation methodology. Two new layouts (Design 1 and Design 2) were evaluated against the current layout. The analysis showed that Design 2 reduced the average operation time per car by 19% (from 117.35 to 95 minutes) and daily cost by 17.7% (from RM1504.36 to RM1237.72). Therefore, Design 2 was recommended for Workshop S. These findings are expected to significantly enhance operational efficiency and cost-effectiveness at their workstations, serving as a model for similar workshops facing layout inefficiencies.