Redesigning Furniture Production Floors Using Systematic Layout Planning and ALDEP Method to Minimize Material Handling Costs

Good equipment and product design are meaningless if there is no good layout planning. Problems owned by PT. Pilar Kekar Plasindo occurs in the production of small polyethylene. This is because small polyethylene production has large material total transfer distance. Small polyethylene problems include the distance between stations, cross-movement, backtracking, and the broken machine that is still placed in the production section. These conditions make the material handling costs and distance large. Therefore, this research aims to produce a layout design of production facilities that can minimize the distance and cost of material movement. The method used in this study is Systematic Layout Planning (SLP). Three alternative designs were compared, and the second proposed facility layout was chosen because it can reduce the total cost of material transfer by 68.3% and reduce the distance of material transfer by 59.6% from the initial facility layout.

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Prayer paper production facility layout redesign using systematic layout planning method and CRAFT

International Journal of Science, Technology & Management ◽

10.46729/ijstm.v1i4.84 ◽

2020 ◽

Vol 1 (4) ◽

pp. 448-456

Author(s):

J Tampubolon ◽

L D Agoestine Simangunsong ◽

M D Agustina Sibuea ◽

A C Sembiring and A Mardhatillah

Keyword(s):

Material Handling ◽

Manufacturing Industry ◽

Raw Materials ◽

Facility Layout ◽

Layout Planning ◽

Unit Distance ◽

Paper Manufacturing ◽

Systematic Layout Planning ◽

Material Handling Costs ◽

The Right

Abstract. The facility layout is a strategic design that is used for a long time. All manufacturing industries must pay attention to the right layout to increase the productivity of the industry. A prayer paper manufacturing industry located in the Tanjung Morawa area, Medan has an error in the placement of raw materials and the placement of production machines, so that the distance from the temporary warehouse to the printing and cutting work stations is far apart, causing high material handling costs. Seeing these problems, research was carried out to improve the layout of the facilities and redesign. The method used for this research is Systematic Layout Planning (SLP), which is one of the methods used to regulate a workplace in a factory by using two areas with high frequency and logical relationships with each other. And the Computerized Relative Allocation of Facilities Technique (CRAFT) Algorithm is a repair program, which is a program that looks for optimal design by making gradual improvements to the layout. CRAFT evaluates the layout by interchanging departmental locations. Inputs required for the CRAFT algorithm include initial layout, data flow or frequency of movement, cost data per unit distance, and the number of departments that do not change or remain. The CRAFT method is usually applied using Quantitative Systems (QS) software. By comparing the layout between SLP and CRAFT, the optimal result is obtained using the SLP method by reducing the distance between departments by 1.407 meters or a distance efficiency of 39.91%.

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Perancangan Tata Letak Stasiun Kerja dengan Menggunakan Metode Systematic Layout Planning

Jurnal Media Teknik dan Sistem Industri ◽

10.35194/jmtsi.v5i2.1480 ◽

2021 ◽

Vol 5 (2) ◽

pp. 118

Author(s):

Elfania Hartari ◽

Dene Herwanto

Keyword(s):

Material Handling ◽

Layout Design ◽

Construction Sector ◽

Material Transfer ◽

Production Lines ◽

Layout Planning ◽

Systematic Layout Planning ◽

Material Handling Costs ◽

The Cost ◽

Initial Layout

PT. Adhimix Precast Indonesia is engaged in the construction sector by producing concrete and construction. Layout design is needed so that the existing land can be utilized optimally and material transfer is more effective and efficient. This can affect the distance and time of the transfer so that the cost of moving can be minimized. In practice, the company's trajectory condition only has one path (trajectory) for alternating current and crossing production lines, so it is considered inefficient to move both goods and workers, coupled with the existence of land that is not used properly, therefore improvements are needed to the production floor layout. in order to minimize the cost of moving goods and have a definite path (trajectory). Systematic Layout Planning (SLP) is a method for redesigning a layout (re-layout) based on the results of distance optimization and Material Handling Costs (OMH). The amount of OMH in the initial layout (now) is Rp. 2,614,200 with a total track distance of 39.82m and OMH in the proposed layout with a total track distance of 19.17m, the result is Rp. 1,534,200, this proves that the proposed layout can be applied because there is a decrease in total OMH by 35.44% or Rp. 926,580. PT. Adhimix Precast Indonesia bergerak di bidang pembangunan dengan memproduksi beton dan konstruksi. Perancangan tata letak diperlukan agar lahan yang ada dapat dimanfaatkan dengan maksimal dan pepindahan material lebih efektif dan efisien. Hal ini dapat mempengaruhi besar jarak dan waktu perpindahan sehingga besar biaya perpindahan dapat diminimalkan. Pada pelaksanaannya kondisi lintasan perusahaan hanya memiliki satu jalur (lintasan) untuk arus bolak balik dan persilangan alur produksi maka dianggap tidak efisien untuk dilakukan perpindahan baik barang maupun pekerja, ditambah dengan adanya lahan yang tidak dimanfaatkan dengan baik oleh karena itu dibutuhkan perbaikan pada layout lantai produksi agar dapat meminimalkan biaya perpindahan barang dan memiliki jalur (lintasan) yang pasti. Systematic Layout Planning (SLP) merupakan metode untuk membuat perancangan ulang suatu layout (re-layout) berdasarkan hasil dari optimalisasi jarak dan Ongkos Material Handling (OMH). Besar OMH pada layout awal (sekarang) adalah Rp 2.614.200 dengan total jarak lintasan 39,82m dan OMH pada layout usulan dengan total jarak lintasan 19,17m didapat hasil sebesar Rp. 1.534.200, hal ini membuktikan bahwa layout usulan dapat diterapkan karena terjadi penurunan total OMH sebesar 35,44% atau Rp.

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Dynamic construction site layout planning: an application of branch and bond algorithm

International Journal of Building Pathology and Adaptation ◽

10.1108/ijbpa-06-2020-0053 ◽

2021 ◽

Vol ahead-of-print (ahead-of-print) ◽

Author(s):

Michael C.P. Sing ◽

Ivan W.H. Fung ◽

David John Edwards ◽

Henry Liu

Keyword(s):

Comparative Analysis ◽

Material Handling ◽

Unit Cost ◽

Real Life ◽

Layout Planning ◽

Content Type ◽

Site Layout ◽

Site Planning ◽

Material Handling Costs ◽

Construction Works

PurposeThis paper develops a platform that can be used to determine how to effectively and efficiently deal with a large number of temporary facilities under a constrained site condition(s). The ultimate goal is to reduce the material handling costs between transformation phases of construction works occurring during the project's development period.Design/methodology/approachEmpirical and deductive research is first adopted to mathematical model dynamic site layout planning using the branch and bond algorithm (B&B). Second, a real-life construction project is examined to illustrate how dynamic site layout planning (using the aforementioned B&B algorithm and a computer software program called LINGO) can reduce the material handling costs. The application of the proposed methodology is then showcased against a case study that utilizes a comparative analysis between the “dynamic” and “statistic” site planning approaches.FindingsBy dividing the construction period into different phases, the developed model is shown to be capable of optimizing the material handling costs between the phases of transformation during construction works. Optimal costs are also considered using the site boundary and unit cost for moving construction materials between two facilities. The comparative analysis results illustrate that the B&B algorithm reduces material handling costs by 33%.Practical implicationsThe proposed model offers an effective planning algorithm for the site layout and location of temporary facilities. More specifically, it can make a substantial improvement in reducing the travel time and material handling cost between the temporary facilities in the construction sites.Originality/valueThe primary knowledge contribution of this study to the site layout is successfully deal with the unequal area problem of temporary site facilities and incorporates the concept of dynamics site planning into the algorithm.

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Usulan Perbaikan Tata Letak Fasilitas Pabrik Tahu dengan Metode Systematic Layout Planning

Jurnal Optimasi Teknik Industri (JOTI) ◽

10.30998/joti.v3i2.10452 ◽

2021 ◽

Vol 3 (2) ◽

pp. 65

Author(s):

Adik Ahmad Unggul Nugeroho

Keyword(s):

Material Handling ◽

Layout Planning ◽

Systematic Layout Planning

Tingkat persaingan yang tinggi dalam industri ini akhirnya mengharuskan untuk menentukan strategi-strategi yang tepat agar dapat menjaga produktivitas sehingga keuntungan yang didapatkan pun dapat terus ditingkatkan. UKM BM adalah salah satu usaha yang bergerak di bidang pengolahan kedelai yaitu memproduksi tahu. Keadaan lantai produksi di UKM BM saat ini masih belum tersusun dengan tepat. Hal ini dapat dilihat pada dari bentuk pola aliran bahan yang ada. Pola aliran yang tidak teratur membuat timbulnya back-tracking dari perpindahan aliran bahan didalam proses produksi yang berdampak pada ongkos material handling. Oleh karena itu perlu adanya suatu pertimbangan bagaimana membuat atau mengubah tata letak fasilitas yang lebih efektif dan efisien, Tujuan dari penelitian ini adalah merekomendasikan suatu rancangan tata letak fasilitas produksi tahu yang baru dengan optimalisasi yang diperoleh dari segi jarak tempuh aliran bahan. Perancangan tata letak menggunakan metode Systematic Layout Planning (SLP) dibuat untuk menyelesaikan permasalahan yang menyangkut berbagai macam permasalahan aliran material produski, transpotasi, pergudangan, supporting, perakitan dan aktivitas kantor adapun hasil dari penelitian ini adalah Jarak material handling pada layout awal yaitu 537.5 meter/ produksi dengan ongkos material handling Rp. 60.000/ produksi. hasil rancangan perbaikan pada layout usulan menunjukan jarak material handling lebih pendek yaitu 424.5 meter/ produksi dengan ongkos material handling Rp. 47.374/ produksi.

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Minimizing Material Handling Costs with the SLP Method and Material Transport Equipment in Steel Pipe Companies

PROZIMA (Productivity Optimization and Manufacturing System Engineering) ◽

10.21070/prozima.v4i2.1310 ◽

2021 ◽

Vol 4 (2) ◽

pp. 10-16

Author(s):

Nur Kalim ◽

Lukmandono

Keyword(s):

Material Handling ◽

Cost Savings ◽

Material Transport ◽

Material Transfer ◽

Transport Equipment ◽

Handling Cost ◽

Material Handling Cost ◽

Systematic Layout Planning ◽

Material Handling Costs ◽

The Cost

Factors that influence the amount of material handling costs are the distance of material movement, methods, and tools (equipment) used. The distance of material movement is strongly influenced by the layout of the production facility. The new layout design using the SLP method is expected to reduce the distance of material or product movement in PT. A B C. From the analysis results obtained the total distance of material transfer at the initial layout of the production process at PT. ABC of 1761 meters / month with material handling costs of Rp. 315,390,000.00 / month. Then an analysis of the use of material transport equipment results in the replacement of a crane with a sloping plane to connect the production machine. So the cost of material handling using the inclined plane becomes Rp. 0. The use of sloping fields can only be used on certain production machines. By using the Systematic Layout Planning (SLP) method, there are 3 alternative layouts produced. The most optimal alternative layout is alternative layout 3 with monthly material handling cost savings of Rp. 68,100,000.00 or 21% of the initial material handling layout cost.

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USULAN TATA LETAK FASILITAS PRODUKSI DENGAN METODE SYSTEMATIC LAYOUT PLANNING

Jurnal Ilmiah Realtech ◽

10.52159/realtech.v15i1.82 ◽

2019 ◽

Vol 15 (1) ◽

pp. 40-46

Author(s):

Andre Lasut ◽

Ronaldo Rottie ◽

Indah Kairupan

Keyword(s):

Material Handling ◽

Layout Planning ◽

Systematic Layout Planning

Perancangan tata letak fasilitas merupakan suatu hal yang penting dalam hal peningkatan produktifitas perusahaan. PT. Meprofarm merupakan perusahaan farmasi di Kota Bandung. Saat ini perusahaan ingin meningkatkan tingkatproduksi terhadap permintaan konsumen khususnya di bagian departemen obat cair. Tata letak perusahaan saat ini tidak optimum untuk meningkatkan produktifitas yang ditandai dengan penempatan tiap ruang produksi tidak sesuai dengan alur produksi. Hal ini menyebabkan arus bolak-balik yang sangat banyak dan dikhawatirkan bahan baku produk obat terjadi kontaminasi dengan lingkungan sekitar. Untuk itu berdasarkan perhitungan dan analisis yang dilakukan menggunakan metode Systematic Layout Planning (SLP) maka perusahaan perlu menambah alat conveyor dan mengubah tata letak yang ada untuk meningkatkan produktifitas serta meminimalkan ongkos material handling. Dari perhitungan yang dilakukan didapat hasil Ongkos Material Handling (OMH) untuk usulan tata letak sebesar Rp. 944.352 dibandingkan dengan tata letak sebelumnya yaitu sebesar Rp. 3.046.695. Jika memakai tata letak usulan maka persahaan dapat menghemat dana sebesar Rp.2.102.343 untuk setiap proses produksinya. Kata Kunci—Perancangan Tata Letak, Tata Letak Fasilitas, Systematic Layout Planning, Ongkos Material Handling.

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Usulan Perbaikan Tata Letak Fasilitas Terhadap Optimalisasi Jarak dan Ongkos Material Handling Dengan Pendekatan Systematic layout planning (SLP) di PT Transplant Indonesia

Jurnal Media Teknik dan Sistem Industri ◽

10.35194/jmtsi.v2i1.327 ◽

2018 ◽

Vol 2 (1) ◽

pp. 45

Author(s):

Dede Muslim ◽

Anita Ilmaniati

Keyword(s):

Material Flow ◽

Material Handling ◽

Layout Design ◽

Flow Path ◽

Material Transfer ◽

Layout Planning ◽

Handling Cost ◽

Material Handling Cost ◽

Systematic Layout Planning ◽

The Cost

Abstract – Unplanned layout and inefficient material flow between work units can lead to increased cost. PT Transplan Indonesia's current material flow path is inefficient with material flow distance 115.5 meters and material handling cost that has not been taken into account. This study aims to find out how big the role of facility layout design in cutting the distance of material transfer and pressing the cost of material handling. The method used in this research is Systematic Layout Planning (SLP) approach, which is comparing the distance of material transfer between initial layout with proposed layout. The results of this study indicate that the distance of the material flow path on the production floor with proposed layout changed to 71,7 meters, with material handling cost per meter reduced from Rp. 1,105,954 to Rp. 712,402 or decrease as much as 35%. Based on the results of the research, the layout of the proposal is considered more effective and efficient because it can reduce the distance of material transfer and reduce the cost of material handling on the packing/shipping floor.Keywords: Layout Design; Material handling cost; Systematic Layout Planning (SLP)

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USULAN PERBAIKAN TATA LETAK PABRIK DAN MATERIAL HANDLING PADA PT. XYZ

Jurnal Ilmiah Teknik Industri ◽

10.24912/jitiuntar.v4i3.1542 ◽

2018 ◽

Vol 4 (3) ◽

Author(s):

I Wayan Sukania ◽

Silvi Ariyanti ◽

Nathaniel .

Keyword(s):

Material Handling ◽

Layout Planning ◽

Systematic Layout Planning

PT. XYZ merupakan sebuah perusahaan yang bergerak di indusustri manufaktur dengan memproduksi mainan plastik. PT. XYZ mempunyai tata letak pabrik dan sistem material handling yang baik namun terdapat masalah yang menyebabkan tata letak pabrik tersebut menjadi berantakan yang diantaranya terjadi ketidak sesuaian letak material bahan baku, material setengah jadi, produk jadi yang menyebabkan banyaknya tumpukan yang memakan ruangan di dalam ruang produksi, dan ruang packaging sehingga untuk mengatasi masalah tersebut perusahaan berencana untuk memperbaiki tata letak pabrik mereka terutama pada bagian ruang produksi dan ruang packaging dengan menggunakan metode Systematic Layout Planning (SLP) agar oabrik menjadi lebih rapi, efektif, dan efisien sehingga dapat meminimalkan waste time dan kegiatan transportasi bahan atau material dari suatu proses ke proses lain sehingga kinerja produktivitas produksi dapat menjadi maksimal. Hasil yang didapat dari analisis sistem material handling adalah indeks pekerja penangganan material secara manual sebesar 0,024 sedangkan hasil analisis sistem material handling dengan menggunakan boxes dan trolley adalah 0,0079.Kata kunci: Tata letak pabrik, material handling, Systematic Layout Planning.

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Rancang Ulang Tata Letak Fasilitas Produksi untuk Efisiensi Produksi Kopi di PT Sinar Mayang Lestari Menggunakan Metode Systematic Layout Planning dan Software Blocplan

Agrikultura ◽

10.24198/agrikultura.v32i2.33610 ◽

2021 ◽

Vol 32 (2) ◽

pp. 146

Author(s):

Muhammad Milzam Abdurrahman ◽

Roni Kastaman ◽

Totok Pudjianto

Keyword(s):

Material Handling ◽

Layout Planning ◽

Systematic Layout Planning

Indonesia masih belum bisa memenuhi permintaan kopi nasional maupun internasional. Total produksi kopi Indonesia pada tahun 2017 sebesar 717.961 ton yang lebih rendah dari kebutuhan kopi Indonesia untuk pasar nasional dan internasional yang mencapai 747.790 ton. Penelitian ini berujuan untuk memperbaiki layout yang ada di PT Sinar Mayang Lestari agar dapat meningkatkan kuantitas dan kualitas produksi kopi PT Sinar Mayang Lestari demi menciptakan produksi yang optimal dan berupaya membantu memenuhi kebutuhan kopi Indonesia. PT Sinar Mayang Lestari merupakan perusahaan penanaman dan pengolahan kopi yang berlokasi di Pangalengan, Kabupaten Bandung. Perancangan ulang tata letak fasilitas produksi PT Sinar Mayang Lestari dilakukan dengan metode Systematic Layout Planning (SLP) dan software Blocplan. Dihasilkan 20 layout alternatif yang dapat dibuat yang kemudian diseleksi untuk menentukan satu layout alternatif yang paling efisien berdasarkan ongkos material handling terkecil. Hasil penelitian menunjukkan layout alternatif hasil metode SLP dengan minimalisasi jarak antar departemen sekitar 33,65% dan pengurangan ongkos material handling sekitar 62,94% dari layout aktual. Perancangan ulang tata letak fasilitas produksi PT. Sinar Mayang Lestari dinilai lebih efektif menggunakan metode SLP dibanding Blocplan karena metode SLP memperhitungkan lebih banyak faktor pendukung daripada metode Blocplan.

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