FACILITIES AND PLANT LAYOUT REDESIGN FOR OPTIMAL EFFECTIVENESS IN WOOD PROCESSING INDUSTRY: A CASE STUDY OF ISEYIN SAWMILL

The wood processing industry in regions like Iseyin, Nigeria, faces significant operational challenges due to outdated facility layouts. These issues contribute to inefficiencies in material handling, elevated production costs, and poor space utilization. This study investigates the impact of facilities and plant layout redesign on operational effectiveness within the wood processing sector, with specific focus on the Iseyin Sawmill in Oyo State, Nigeria. The initial assessments revealed that the pre-existing layout created inefficiencies such as long material handling distances, underutilized floor areas, and poor workflow design, all of which negatively affected productivity and employee morale. A mixed-method research design was employed, integrating qualitative observation with quantitative analysis of data from 120 workers. The research utilized layout flow diagrams, distance charts, production logs, and employee feedback forms to evaluate both the original and redesigned layouts. Post-redesign analysis revealed notable improvements. Material handling distances across operational sections (cutting, sawing, drying, and packaging) were reduced by up to 320 meters. Daily production output increased by an average of 25%, rising from 120–130 units to 160–173 units per day across a typical workweek. Space utilization improved significantly, from 65% to 85%, as verified by facility floor analysis and visualized through pie charts. Additionally, employee satisfaction increased by 3.5 points, with positive feedback on ergonomics, workflow, safety, and reduced stress. Agreement levels among workers improved from an average of 18% to over 94%. However, demographic data showed most workers were aged 30–49 and had 5–10 years of experience, including machine operators (50%), supervisors (25%), maintenance staff (8%), and administrative/other roles (17%). These findings confirm that the redesign was well-received by a skilled and experienced workforce. Analytical models used to measure workflow and space efficiency affirmed the benefits of lean layout principles and ergonomic improvements, aligning with the objective of inclusive evaluation. The study emphasizes the strategic value of systematic layout redesign in enhancing productivity, safety, and employee satisfaction. It proposes a replicable model for small- and medium-scale manufacturing enterprises seeking to improve spatial efficiency and operational outcomes through structured facility planning.