Strategic Plant Redesign in the Glass Industry: A Case Study Applying SLP and Discrete Simulation

The study focuses on the redesign of the plant layout of a glass manufacturing company using the systematic layout planning (SLP) methodology and discrete event simulation (DES). Deficiencies in the current layout were identified, such as inefficient material flows and excessive distances travelled by workers. Detailed data on dimensions and operating times were collected and analysed using tools such as Stat-Fit to statistically validate the data and simulate it in FlexSim V 22.2.0. The SLP methodology allowed the identification of relationships between areas and the proposal of three alternative layout designs. The selected layout, with 90% material flow efficiency, significantly reduced the distances travelled by operators and improved organisation and location. Simulation results showed an average reduction of 52% in the distances travelled by workers, as well as a better distribution of workloads. This study demonstrates how the integration of simulation and systematic planning tools can improve operational efficiency and productivity in manufacturing companies.