scholarly journals Analysis of Bread Production Facilities Layout using BLOCPLAN Algorithm

2021 ◽  
Vol 10 (2) ◽  
pp. 172-181
Author(s):  
Harry Imanullah ◽  
◽  
Hesty Heryani ◽  
Agung Nugroho ◽  
◽  
...  
Keyword(s):  
Material Handling ◽  
Production Capacity ◽  
Transfer Time ◽  
Material Transfer ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Bread Production ◽  
The One ◽  
Initial Layout ◽  
Production Facilities

This study aims to obtain an optimal facility layout by considering the distance between the workstations, transfer time, and material handling cost in a bakery. The research was conducted at a medium-scale bread producer CV Mumtaz Bakery in Banjarbaru City, South Kalimantan. The initial layout of CV Mumtaz Bakery's production facilities is considered as not optimal for production capacity up to 500 kg per day. The layout analysis and the appearance of improvement alternatives were carried out using the BLOCPLAN algorithm, and then the design implementation was carried out using CorelDraw software. Determination of the best layout alternative is based on the highest R-Score. The results showed that the best layout was the one with an R-Score of 0.86. This selected workstation layout has a total distance between processing stations of 31.70 m, a total transfer time of 25 seconds, and a material handling cost of IDR 434.29 for each batch. This layout will reduce the total material transfer distance and the material transfer time from the initial layout by 14.67% and 10.7% respectively.

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

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.

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

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)

scholarly journals Analisa Perbaikan Tata Letak Penempatan Bahan Bakudi Area Gudang Penyimpanan

2021 ◽  
Vol 10 (2) ◽  
Author(s):  
Beni Harma ◽  
Helga Ika Sudra
Keyword(s):  
Material Handling ◽  
Raw Materials ◽  
Layout Design ◽  
Raw Material ◽  
Storage Method ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Method Class ◽  
Material Handling Costs ◽  
Initial Layout

Activities carried out in the warehouse include material handling. Generally, the costs involved in material handling activities are quite large. One method that can be used in managing the layout of raw material placement in raw material warehouses is the class based storage method. Class based storage is a policy that divides storage into three classes A, B and C based on Pareto law. Pareto law is the principle of putting items that have the greatest accessibility near the Input-Output point. The distance of material handling to the initial layout raw material warehouse is 3,513,337 meters / month and the material handling costs are Rp. 134,534,765 / month, because the initial layout of the raw material warehouse still uses random storage and the raw materials that are widely used are not placed close to the intake floor of the production, so that the distance to get raw materials for production needs is far. After the re-layout design was made based on the placement of raw materials in the class based storage method, the material handling transfer distance was reduced to 2,644,459 meters / month and the material handling cost for the repair raw material warehouse layout fell to Rp. 99,949,520 / month. In other words, there was a decrease in material handling distance by 25% and material handling costs by 26%.

Optimisation of Facility Layout Problem at Automotive Industry a Case Study in Sabah

2013 ◽  
Vol 315 ◽  
pp. 755-761 ◽  
Author(s):  
Kah Song Tan ◽  
Noor Ajian Mohd-Lair ◽  
Stephen Yong Nai-Vun ◽  
James Yong Chau-Leong
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Production Capacity ◽  
Layout Problem ◽  
Throughput Time ◽  
Facility Layout Problem ◽  
Manufacturing Line ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Arena Simulation

The general Facility Layout Problem deals with the arrangement of machines within the facility based on the constraints such as material flow distance, volume of flow of products, material handling cost and operation sequence of product. The facility layout problem is directly linked with the efficiency of the facility or the manufacturing line. The objective of this project is to design a simulation based methodology experiment on designing an optimized facility layout and evaluating the proposed alternative layouts using ARENA simulation. This project is conducted at Benteng Motor Sdn. Bhd. in Kota Kinabalu, Sabah. Currently, the company is planning to expand their manufacturing plant and hence the company needs an optimized facility layout to maximize the product capacity and manufacturing throughput time on a minimum utilization of resources environment. An eight steps simulation methodology is being proposed to design an optimized facility layout. A manufacturing re-engineering scenario has been developed to improve the existing system. The proposed scenario was evaluated using Arena simulation student package. The scenario has significantly increases the production capacity up to 225%, decrease the manufacturing throughput time by 19% as well as increase the utilization of majority of the manufacturing resources more than 200%.

scholarly journals Monarch Butterfly Optimization for Facility Layout Design Based on a Single Loop Material Handling Path

Mathematics ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 154 ◽  
Author(s):  
Minhee Kim ◽  
Junjae Chae
Keyword(s):  
Material Flow ◽  
Material Handling ◽  
Facility Layout ◽  
Monarch Butterfly ◽  
Layout Design ◽  
Monarch Butterfly Optimization ◽  
Single Loop ◽  
Handling Cost ◽  
Material Handling Cost ◽  
The Given

Facility layout problems (FLPs) are concerned with the non-overlapping arrangement of facilities. The objective of many FLP-based studies is to minimize the total material handling cost between facilities, which are considered as rectangular blocks of given space. However, it is important to integrate a layout design associated with continual material flow when the system uses circulating material handling equipment. The present study proposes approaches to solve the layout design and shortest single loop material handling path. Monarch butterfly optimization (MBO), a recently-announced meta-heuristic algorithm, is applied to determine the layout configuration. A loop construction method is proposed to construct a single loop material handling path for the given layout in every MBO iteration. A slicing tree structure (STS) is used to represent the layout configuration in solution form. A total of 11 instances are tested to evaluate the algorithm’s performance. The proposed approach generates solutions as intended within a reasonable amount of time.

scholarly journals MATERIAL FLOW ANALYSIS AND PLANT LAY-OUT OPTIMIZATION OF A MANUFACTURING SYSTEM

2014 ◽  
pp. 107-116
Author(s):  
Francesco Longo ◽  
Giovanni Mirabelli ◽  
Enrico Papoff
Keyword(s):  
Material Flow ◽  
Material Handling ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Wood Products ◽  
New Production ◽  
Accurate Analysis ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Time Minimization

The paper proposes the results of a research project developed by the authors in collaboration with a production system working in the field of manufacturing wood products. The first step of the project was an accurate analysis of the system and the design of new production documents in order to collect data about the system itself. The collected data have been used to propose an initial solution of plant lay-out. The second step of the project was the construction of a simulation model. The model has been used to find an optimal plant- layout configuration by means of genetic algorithms with the goal of material handling cost and shop order flow time minimization.

scholarly journals Perancangan Tata Letak Stasiun Kerja dengan Menggunakan Metode Systematic Layout Planning

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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