Facility layout planning through the ALDEP Method in the wooden cable reels industry

Facility layout planning plays a pivotal role in manufacturing system design, impacting vital metrics such as lead time, handling costs, and space optimization. While a significant portion of research has been invested in refining existing facility layouts, there is a noticeable research gap in devising optimized layouts for new establishments, especially in the value-added wood products domain. Addressing this lacuna, this research focused on designing an efficient department-level layout for a wooden cable drums manufacturing facility in an area of 4150 m2. This facility included both office and production areas. The investigative process was segmented into four distinct phases: Deciding the strategic positioning of the facility on the available plot, defining the functional and spatial requirements for each department, establishing the intricate relationship dynamics between these individual units, and rigorously documenting the most optimal department-level facility layout. For precision in layout creation, the ALDEP algorithm was employed, which was further visualized to offer a comprehensive three-dimensional representation. The final layout seamlessly organized seven departments within the 1st Floor Office Area, eight in the 2nd Floor Office Area, and thirteen within the Production Floor. Efficiency evaluation of these areas yielded scores of -811, 184, and -318, respectively. Conclusively, this research furnished actionable insights for manufacturers within the wood products sector and was expected to be an invaluable reference for academics delving into facility planning and value-added wood products manufacturing.