Facility Layout Optimization for a Garment Manufacturing Plant in Anambra State

Inefficient facility layouts in Nigerian garment manufacturing plants increase material handling costs, extend production cycle times, and reduce throughput, particularly in small and medium-scale enterprises where space is limited. This study applies systematic layout planning (SLP) and the load-distance model to optimize the facility layout of a garment manufacturing plant in Anambra State, South East Nigeria. The plant's current layout accommodates 11 production departments across a 2,400 square metre floor area. From-to flow charts and activity relationship diagrams are developed based on observed material flow volumes and operational adjacency requirements gathered through plant observation and management interviews. The load-distance score of the current layout is computed and compared against alternative layout configurations generated through block layout planning. Three alternative layouts are evaluated using both load-distance minimization and qualitative adjacency scores. Results indicate that the proposed layout alternative two reduces the total load-distance score by 34 percent compared to the current arrangement, primarily by relocating high-traffic intermediate processing areas closer to cutting and sewing stations. The qualitative adjacency analysis further confirms that the proposed layout better satisfies operational flow and safety requirements. Recommendations include phased implementation of the layout change to avoid production disruption and investment in flexible workstation furniture to facilitate future rearrangements. This research demonstrates the substantial efficiency gains achievable through systematic layout planning in South East Nigerian manufacturing. Keywords: facility layout, load-distance model, systematic layout planning, garment manufacturing, Anambra State