Sustainable Optimization of Industrial Plant Layouts: A Systematic Review of Methodologies, Tools, and Indicators

In a global landscape increasingly driven by competitiveness and sustainability, manufacturing companies face significant challenges in adopting sustainable practices—often due to financial limitations, limited technical training, and inadequate policy support. This study presents a systematic literature review focused on methodologies, tools, and performance indicators used to optimize industrial plant layout, with a particular emphasis on enhancing operational efficiency and environmental sustainability. Using Fink’s methodology, 46 peer-reviewed articles published between 2014 and 2024 were rigorously analyzed through a three-tier bibliometric approach: meta-analysis, keyword clustering, and descriptive sample analysis. The findings highlight the effectiveness of hybrid strategies that integrate systematic layout planning (SLP), advanced simulation platforms (FlexSim, Arena, ProModel), and multi-criteria decision-making techniques (AHP, NSGA-III). These approaches demonstrate clear improvements in workflow efficiency, bottleneck reduction, and environmental impact mitigation. Key performance indicators identified include material flow, travel distance, cycle time, inventory levels, and carbon footprint. The study underscores the importance of integrated methodologies that align operational and sustainability objectives, offering valuable insights for decision-making in industrial engineering and facility planning goals.