Facility Layout Optimisation for a Textile Manufacturing Firm in Kano State

This project investigates the current facility layout of a selected textile manufacturing firm in Kano State, North West Nigeria, with the objective of identifying inefficiencies and proposing an optimised arrangement. The textile industry in Kano has historically been a major employer and economic driver; however, persistent challenges related to material handling distances, idle workstation time, and congested production floors have reduced operational efficiency in recent years. This study adopts a descriptive survey approach, combining plant observation, flow process charting, and from-to chart analysis to map existing material flows. Data were obtained through direct measurement and structured interviews with production supervisors over an eight-week period. The study evaluates three alternative layout configurations using the Systematic Layout Planning methodology and selects the most efficient arrangement based on minimised total weighted distance and improved throughput. Results indicate that a cellular manufacturing layout reduces inter-departmental travel distance by an estimated thirty-eight percent compared to the existing process layout. The research also highlights the importance of aligning layout decisions with production volume variability and workforce ergonomics. Practical recommendations are provided for implementation within the firm's capital constraints. This study is relevant to small and medium-scale manufacturers across the North West zone seeking cost-effective layout improvements without major capital expenditure. Keywords: facility layout, Systematic Layout Planning, textile manufacturing, Kano State, material handling