Abstract

The garment industry plays a crucial role in the economy’s overall growth by manufacturing the quality of clothes being sold worldwide. But despite playing a crucial role in economic growth, the industry experiences idle Times that affects productivity. The goal of this study is to identify the factors that cause delays and  propose an optimized facility layout that helps enhance the productivity and efficiency of the whole production. Moreover, this study offers a comprehensive analysis of the impact of facility layout on manufacturing productivity, specifically on garment manufacturing production of two-way colored shirts. Additionally, this study uses qualitative and quantitative research methodologies, including the time and motion study (T.M.S.) method and ProModel Simulation software, to analyze the production process. This paper observed and interviewed workers at garment manufacturing companies and validated the present and proposed facility layout for garment manufacturing companies using ProModel Simulation software. After simulating, the study indicates that the proposed production layout significantly increased production capacity, elevating the hourly production rate by 4.62 times. This means there is a significant increase in the production efficiency and output of garment manufacturing, with the ability to produce 231 shirts within an eight-hour shift compared to the previous 50 shirts. Future research of this study will consider other layouts theory approaches such as U-shaped layout and Cellular layout.  This paper presents the crucial role of strategic facility layout planning in manufacturing processes, offers valuable insights for similar industries aiming to enhance their manufacturing productivity, and demonstrates the potential for substantial improvements in operational efficiency and output through layout optimization.