# Strategic Plant Redesign in the Glass Industry: A Case Study Applying SLP and Discrete Simulation
###### Abstract  
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. 10 March 202510  
To reduce production costs and optimise operating times, it is essential to achieve a proper balance between man, machine and material, which can be achieved through an efficient plant layout design in industry [6]. According to [7], the effectiveness of production factors is maximised when they operate in an appropriate space, which allows the manufacturing processes to be controlled and secured. Therefore, it is essential to implement a distribution scheme per workstation and operation that minimises high production costs and reduces time and productivity loss, which are common problems in the industry that can be solved with proper space planning [8]. In general, manufacturing industries play a key role in the overall economic development of countries, especially the glass industry, providing essential materials for multiple sectors, from construction to advanced technology. Internationally, demand for glass products continues to grow, driven by technological innovations and sustainable infrastructure needs [9]. However, to remain competitive in this dynamic market, companies in the sector face the constant challenge of optimising their production processes and operational efficiency. In the national context, the glass industry in countries such as Colombia has shown a significant evolution, adapting to sustainability and energy efficiency trends, highlighting the importance of advanced manufacturing practices. Systematic layout planning (SLP), developed by [PERSON] in 1968, is a key methodology to maximise resource efficiency by strategically organising work areas and industrial equipment [7; 10]. This tool combines quantitative and qualitative analyses, encompassing not only the physical dimensions of the plant, but also the interrelationships between areas, material flow, worker ergonomics, and specific process and storage requirements [11]. By integrating these aspects, SLP fosters competitiveness and continuous improvement, helping organisations to respond effectively to the demands of an ever-changing industrial environment [12]. According to the authors of [13], they used the systematic layout planning (SLP) technique to develop an optimised plant layout. This methodology allowed for a detailed analysis of the material flow and interrelationships between activities, resulting in a significant reduction in distances travelled and an increase in productivity. As a result, a design was selected that reduced the total distance travelled during manufacturing by 339.05 metres. In addition, material flow was optimised by integrating previously separate areas and eliminating waste associated with movement and transportation. Together, these improvements contributed to a marked increase in overall plant productivity. According to [14], the implementation of the systematic layout planning (SLP) methodology resulted in a 10.06% increase in freed space, reaching a total of 2.16 m\({}^{2}\).