Analysis of Bread Production Facilities Layout using BLOCPLAN Algorithm

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.

Analisa Perbaikan Tata Letak Penempatan Bahan Bakudi Area Gudang Penyimpanan

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%.

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

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.

A Genetic Algorithm for the Double Row Layout Problem

The double row layout problem (DRLP) is an NP-hard and has many applications in the industry. The problem concerns on arranging the position of machines on the two rows so that the material handling cost is minimized. Although several mathematical programming models and local heuristics have been previously proposed, there is still a requirement to develop an approach that can solve the problem efficiently. Here, a genetic algorithm is proposed, which is aimed to solve the DRLP in a reasonable and applicable time. The performances of the proposed method, both its obtained objective values and computational time, are evaluated by comparing it with the existing mathematical programming model. The results demonstrate that the proposed GA can find relatively high-quality solutions in much shorter time than the mathematical programming model, especially in the problem with large number of machines.

Efektivitas Tata Letak Gudang Baru untuk Menekan Tingkat Kerusakan Produk Menggunakan Metode Class Based Storage

Abstract— U.D. BAROKAH is engaged in the fulfillment of agricultural needs that will move products from the old warehouse to the new warehouse, products include: fertilizers (subsidies and non-subsidies), seeds, and pesticides. The old warehouse with an area of 150m2 and a new warehouse that has an area of 400m2. To streamline the new space and hopefully can reduce the level of damage to the product then, layout layout design is made using 2 methods of ABC classification and Class Based Storage Method. The product is placed in accordance with its activities, looking at the demand of November 2017 which shows the percentage value close to grade A 80%, B15%, and C5% grade. So make the area block based on the class, the area of the block area used class A 49m2, B 14m2, and C10m2. From the results calculated to determine the effectiveness of the warehouse mathematically by using the calculation of Material Handling Cost, the result of the calculation is Rp 375.321,60 per month.Keywords : ABC Classification , Class Based Storage, and Material Handling Cost Abstrak— U.D. BAROKAH yang bergerak dalam bidang pemenuhan kebutuhan pertanian yang akan memindahkan produk dari gudang lama ke gudang yang baru, produk meliputi: pupuk (subsidi dan non subsidi), bibit, dan pestisida. Gudang lama dengan luas 150m2 dan gudang baru yang mempunyai luas 400 m2. Untuk mengefektifkan luas ruangan baru dan diharapkan bisa menekan tingkat kerusakan pada produk maka, perancangan tata letak layout dibuat menggunakan 2 metode yaitu klasifikasi ABC dan Metode Class Based Storage. Produk ditempatkan sesuai dengan aktifitasnya, melihat dari permintaan bulan November 2017 yang menunjukan nilai persentase mendekati untuk kelas A 80%, B 15% , dan kelas C 5%. Sehingga di buatlah blok area berdasarkan kelas tersebut, luas block area yang terpakai kelas A 49 m2, B 14m2, dan C 10 m2. Dari hasil tersebut dihitung untuk mengetahui efektifitas gudang secara matematis dengan menggunakan perhitungan Ongkos Material Handling, hasil dari pehitungan tersebut adalah Rp 375.321,60 per bulan.Kata kunci : Klasifikasi ABC, Class Based Storage, Ongkos Material Handling

PENERAPAN WAREHOUSE MANAGEMENT SYSTEM PADA PT UNIPLASTINDO INTERBUANA BALI

Warehouse Management System is a database-based computer application system, which used to improve warehouse efficiency in maintaining the accuracy of inventory data by recording every transaction in the warehouse. The purpose of this study was to determine efficiency of material handling costs incurred after implementation of warehouse management system. The research was conducted at PT Uniplastindo Interbuana Bali with simulation of implementation warehouse management system. Based on calculations, application of WMS able to increase cost efficiency and time efficiency in material handling because the system is able to provide accurate material placement data. Data during simulation shows a smaller amount of time compared to before simulation, which means less costs are incurred. Existence of system also makes it easy for related admin to collect data on real stock in the field. Data presentation and processing becomes faster and accurate so it can lead to increased performance in company. Keywords: Warehouse Management System (WMS), material handling, cost efficiency

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

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.

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

– 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)