Translating Manufacturing Complexity into Layout Decisions: A Decision-Support Framework for Intralogistics Layout Redesign in High-Mix Manufacturing

Background: High-mix manufacturing environments are characterized by increasing product variety, dynamic material flows, and growing operational complexity, creating significant challenges for intralogistics layout redesign. Existing research addresses manufacturing complexity, facility layout planning, simulation, and multi-criteria decision-making; however, these approaches are typically applied independently and provide limited guidance for systematically translating manufacturing complexity into layout redesign decisions. Methods: This study proposes the Complexity-Driven Intralogistics Layout Redesign Framework (CDILRF), which integrates manufacturing complexity assessment, Complexity Translation, layout design, digital layout evaluation, and structured decision support into a unified redesign methodology. The framework was demonstrated through an industrial case study in a high-mix automotive manufacturing environment. Results: The framework transformed manufacturing complexity into structured layout redesign requirements, supported the evaluation of five layout alternatives, and identified the preferred redesign solution digital material-flow analysis and multi-criteria assessment. The selected layout reduced logistics effort by approximately 37% while increasing available warehouse space. Conclusions: CDILRF establishes an explicit link between manufacturing complexity assessment and intralogistics layout redesign through a structured, transparent decision-support process. The framework contributes to manufacturing logistics research and provides a practical methodology for data-driven intralogistics layout redesign in high-mix manufacturing environments.