In this paper, a simulation-based strategy has been used to optimize the layout and manpower optimization to improve plant performance. Key objects include evaluating the existing plant layout, workforce availability. By focusing on these objectives, the work involves in modeling and analyzing the ideal layouts, and workforce configurations using discrete event simulation. The simulation-based methodology is used for thorough examination of multiple scenarios to enhance the plant's performance through optimized layout and workforce allocation. Through modeling and analyzing the existing plant layout in the simulation software, it is observed that the total lead time is 5 days, 10 h, and 45 min and total manpower is 13 in shift -1 and 7 in shift-2 and underutilized space is 23.25%. It is observed that integration of new furnaces to the existing plant has increased lead time to 5 days, 19 h, and 52 min. After thorough analysis and simulation runs, new layout is proposed. In the newly proposed layout, it is concluded that total lead time is 5 days, 9 h and 57 min and optimized manpower is 18 in shift-1 and 10 in shift-2 and the underutilized space is reduced to 10.4%. The lead time is reduced to 129.95 h from 139.8 h, the manpower is increased from 20 to 28 per day and unutilized space is reduced to 10.4% from 23.25%. The work aims to contribute valuable insights to layout and manpower optimization as per industry need, by offering a practical and adaptable methodology for operational excellence.