Layout Of Production Facilities Research Articles

Systematic Layout Planning to Improve Facility Layout in Small and Medium Food Enterprise

The absence of a structured method for revamping current or introducing new production layouts in small and medium-sized enterprises may hinder the flexibility and competitiveness of the enterprise. This study aimed to assess the existing production layout and offer improvement recommendations for a small and medium-sized food enterprise in East Java, Indonesia. Data was obtained through interviews with the owner and observation at the production site. The research employed systematic layout planning, utilizing activity relationship charts and diagrams. The findings presented two alternative suggestions for the production facility layout, with the study recommending the second alternative based on an evaluation of criteria. The second proposed alternative exhibited a total material handling distance per week of 1,812 and a total material handling cost of 17,961.96 rupiah, lower than the first proposed alternative. The managerial implications of this study pertain to the construction of facilities with a focus on technical and hygiene requirements, the design and layout of buildings and rooms, and the requirements for machinery, equipment, and transportation to ensure product quality and safety.

Redesign The Layout of Production Facilities at a Garment Company Using the BLOCPLAN Method to Optimize Material Handling

Facility layout design is crucial in production layout setups. The composition of facilities that corresponds to the flow of materials between departments will help to ensure the production system's continuity. PT. KMC is a garment company in West Jakarta that manufactures shirts, dresses, and t-shirt bloats. The company's current layout facilities have not run optimally. This is because inefficient movement distances result in wasted material handling costs, and crossing production flows between departments cause production processes to be disturbed. The objective of this project is to rethink facility layouts using the BLOCPLAN approach in order to optimize material handling. The BLOCPLAN approach may examine layout performance and generate new layout ideas for efficient material handling. The discussion is limited because this research was only conducted on one company. Based on the results of the layout redesign using the BLOCPLAN approach, various improvements were obtained, including a 37.12% increase in material handling cost efficiency. The proposed layout with the BLOCPLAN method is able to provide a reduction in material transfer distance of 22.6 meters and a material handling cost of Rp 155,346 when compared to the initial layout, which had a total overall displacement distance of 35.8 meters and an initial layout material handling cost of Rp 247,059, making it much cheaper.

Redesign of Wallet Production Facility Layout Using ARC and Simulation at Fanri Collection

Abstract. The development of technology at this time causes competition in the accessories and fashion industry. This situation has caused an increase in the number of requests for products at Fanri Collection, a producer of leather craft accessories. To survive and win the competition, companies need to increase productivity. One way of resolving the issue is by designing the layout and production facilities to minimize the distance of material handling in the production process. This research aims to design layout and production facilities on wallet products with the Discrete Event Simulation (DES) method using FlexSim 21.0 software and Activity Relationship Chart (ARC) to analyze the amount of output and get a proposed facility layout. Based on the simulation results, in producing 200 units of wallets, the initial total material handling distance is 20.667 meters with a cycle time of 1 day, 5 hours, and 3 minutes. After making improvements with ARC, the total material handling distance is reduced to 17.475 meters with a cycle time of 1 day, 4 hours, and 48 minutes. Thus, the improvement can minimize material handling distance by 3.192 meters and reduce cycle time by about 15 minutes.

Redesign Layout of Production Facilities Using Systematic Layout Planning and ARC Methods at UMKM Bill Bakerykoe

Redesign Layout of Production Facilities Using Systematic Layout Planning and ARC Methods at UMKM Bill Bakerykoe

Usulan Perancangan Tata Letak Fasilitas Produksi Dengan Metode BLOCPLAN Untuk Meningkatkan Produktivitas CV. Madu Apiari Mutiara

CV. Madu Apiari Mutiara is a company that operates in the field of derivative honey products such as pure honey, candy, soap, and health products such as propolis and other derivative products which have various shapes and compositions. This condition makes it necessary to have the most efficient spatial layout of work areas and production facilities in order to increase work morale and work productivity in terms of the layout of production facilities. The method used to solve this problem is the BLOCPLAN method. This method can solve facility layout problems in CV Madu Apiari Mutiara production houses with the level of close relationship, area requirements, taking into account the distance of material movement and final layout. The area on CV. Madu Apiari Mutiara is 100 m2, the total area requirement is 70.48 m2. There are 3 alternative layouts in the BLOCPLAN method, the proposed layout chosen is based on the R-Score value which is close to 1, namely the 2nd layout with a material movement distance efficiency of 8.1 meters or 20.9%.

Facility layout design improvement in bottled drinking water at teaching factory

The Bottled Drinking Water Teaching Factory (Tefa) at State Polytechnic of Jember (Polije) produces mineral water packaged in several sizes of bottles, glasses, and gallons. The efficiency and effectiveness of the bottled drinking water production process is influenced by the layout of production facilities. The mismatch of machine layout arrangement and the number of unused equipment causes material flow to be longer. This study aims to redesign the layout of the Tefa Bottled Drinking Water facility to maximize area utilization and reduce empty space. This research provides recommendations for facility layout improvements using the Systematic layout planning (SLP) method. Alternative designs were proposed and compared the performance of each design with the initial layout. The results of the proposed method’s distance processing affect the total material handling cost. The total distance of the proposed method facility is 11.7 meters while the distance of the current facility is 28.8 meters so that can save material handling costs by 59%.

The Implementation of Hazard Analysis Critical Control Points in the Amplang Production Process at UMKM X, Balikpapan

Background: Amplang is a snack made primarily from fish and is usually given as souvenirs to tourists, especially in Balikpapan. The process of making amplang involves a fairly long process, that might lead to bacterial growth if not handled correctly. Therefore, Hazard Analysis and Critical Control Point is one of the methods that can be used to prevent food contamination. Purpose: The purpose of this research is to assess the Hazard Analysis and Critical Control Point implementation in the production process of amplang by Micro, Small, and Medium Enterprises of X in Balikpapan. Method: This research is qualitative in nature with a case study approach. The informants in this study were the owners and employees of Micro, Small, and Medium Enterprises of X who are responsible for the amplang production process from fish meat storage to packaging. Results and Discussion: The formulation of the Hazard Analysis and Critical Control Point stages indicates that the critical point is in the fish meat grinding process. Based on the bacterial testing results at each stage of amplang production in Micro, Small, and Medium Enterprises of X, it meets the requirements of SNI 7763:2013. Micro, Small, and Medium Enterprises of X has implemented the Hazard Analysis and Critical Control Point system effectively. To maintain and improve the existing conditions, it is recommended that the owner chooses suppliers of fresh fish raw materials who also implement food safety and personal hygiene systems. The production facility layout should be organized according to the 5R/5S principles to prevent contamination of raw materials and ensure the safety of Micro, Small, and Medium Enterprises of X workers.

FOOD SAFETY RISK ANALYSIS IN MSME PRODUCT SUPPLY CHAIN FROM SCOR, SIX SIGMA AND HACCP INTEGRATION

MSME baster is a business that is engaged in food, especially meatballs. This MSME baster needs to regulate foodprocessing which aims to avoid chemical microbial contamination and others. Starting from raw materials,processing to consumption by consumers, attention is also given to maintaining product safety. The method used indesigning the layout of production facilities at MSME Baster is the integration of Scor, six sigma and Haccp. TheScore method was chosen because it performs and decomposes the process, can measure the supply chain objectivelybased on existing data and can identify improvements that need to be made to create competitive advantage, the SixSigma method to identify problems in the production process and describe the shortcomings in terms of time, money,customers and opportunities, Haccp can reduce the level of risk to morbidity and mortality associated with theconsumption of unsafe food. From the results in the process of making meatballs, there are 3 types that have beendescribed at the determining stage, namely rotten material, material contaminated with fungi, material contaminatedwith the Pareto diagram, it is known that 39% can cause harm to food is control that comes from the upper limit(UCL) of 0.06271 (LCL) of 0.038 with P (average proportion) of 0.07348363, which means that what happened to thecompany the average proportion was 0.07 or 7%

Analysis Planning Relay Layout with Computerized Relative Allocation of Facilities Technique Approach

PT XYZ is one of the manufacturing industries engaged in the production of palm oil processing. The products produced are cooking oil and margarine. So far, the implementation of activities has been hampered by the current layout conditions having a less efficient material handling path length, in addition, the distance between facilities is too far ± 150m which results in repeated transportation, this results in PT XYZ's material transfer activities being less effective. Therefore, this study aims to redesign the layout of production facilities in order to minimize material handling costs and raw material movement distances to be more effective. From these problems, the method used is the CRAFT (Computerized Relative Allocation of Facilities Techniques) method, this method can be done with the help of FTC (From to Chart), ARC (Activity Relation Chart) and ARD (Activity Relationship Diagram) calculations. The results of this study showed that the CRAFT algorithm succeeded in saving total material handling costs of Rp. 469,352.04 per day and reducing the total distance of movement by 67.15 meters. The reduction in material handling costs achieved was Rp 2,114,734.77 or around 81.84%, while the reduction in material handling distance reached 306.85 meters or around 82.05%.

Planning of Production Facilities Layouts of Home Industry of Cabalu Smoked Salted Egg in Bone District

The home industry of Cabalu smoked salted egg is one of the home industries in Bone Regency that operates in the egg processing sector. This home had the potential to produce smoked salted eggs, which was quite promising and was supported by the main raw material for duck eggs, which was available in three cages in Cabalu village and had a group of ducks and raw materials for salt that are easy to obtain, as well as the public's interest in home products. Currently, the layout of production facilities and working environment conditions in the home industry of Cabalu smoked salted egg are experiencing problems. This research aims to redesign the Home Industry of Cabalu smoked salted egg facility's layout, which can utilize the area, minimize material path length, reduce process constraints, and maximize production results using the Activity Relationship Chart (ARC) method and the BLOCPLAN algorithm. The proposed layout was selected based on the adjective value and R-Score, which was close to 1, with a rel-dist score with the lowest value and adapting to the conditions of the home industry. The proposed layout number 20, the alternative layout was chosen as the proposed layout with the lowest material transfer distance.

Desain Optimal Tata Letak Fasilitas Dengan Menggunakan Metode CORELAP dan Algoritma CRAFT

UD. Doa Emak is an appropriate technology business engaged in the manufacture of tools or machines of various models and sizes. UD Doa Emak accepts production requests that vary according to customer requests. There is increasing customer demand and product variations, UD owners. Doa Emak expands the production area so that currently there is empty land that has not been utilized. The land area owned by UD. Doa Emak is 623 m2 with a percentage of vacant land of 48%. By utilizing vacant land, it is possible to increase utilities and optimize machine arrangement so that the transfer distance becomes more efficient and production capacity will increase. This research will solve the problem of production facility layout by redesigning the layout using the CORELAP (Computerized Relationship Layout Program) method, the CRAFT Algorithm (Computerized Relative Allocation of Facilities Techniques) and will be simulated with Flexsim Simulation to provide alternative decisions on the proposed layout. From this study, the results of the CRAFT method were more optimal than the initial layout with a large OMH depreciation of Rp. 49662,6 and efficiency percentage of 3,29%. Simulations using flexsim software produced a total traveled of 115843 m/month.

Optimization of Facility Layout Problems Using Genetic Algorithm

The facility layout problem (FLP) is one of the most important classic industrial engineering and production management problems that have attracted the attention of many researchers over the last few decades. Poor production facility layout planning can result in additional operational costs; one of them is the cost of material handling. Although crucial, FLP is a challenging issue to resolve. A unique method is needed depending on the constraint, case study, and layout type. This research was conducted in order to improve the existing layout of PT. XYZ to minimize material handling costs. The layout type in this case is the Open-field layout problem (OFLP). A genetic algorithm is proposed to optimize the layout. The result is 18.1% material handling costs can be reduced.

Perancangan Ulang Tata Letak pada Galangan Kapal Tradisional menggunakan Blocplan-90

CV. Rasya Jaya is a traditional fishing boat manufacturing company located in Padang Seurahet, Kec. Johan Pahlawan, Aceh Barat Regency. The facility layout of CV. Rasya Jaya has several workstations that are not in the correct location for the production process or the relationship between related rooms. This results in inefficient and ineffective material handling, as well as reduced worker comfort. The poorly organized facilities also contribute to production constraints. Therefore, it is necessary to evaluate the production facility layout at CV. Rasya Jaya. The goal is to provide an alternative design for the production facility layout that is more efficient and effective in terms of the relationship between the production process flow and minimizing material flow in the production process. The purpose of this study is to determine the optimal layout at CV. Rasya Jaya using the Blocplan algorithm. Blocplan-90 is an algorithm for solving spatial layout problems that can handle both quantitative and qualitative data. Mathematical models within the design are developed with computer applications for models that work with the limitations of workstation shapes. Based on the results of the layout design of facilities at CV. Rasya Jaya, three main layouts were created: office layout, facility layout, and production layout. The total area of the three layouts is 1739 m2.

Определение взрывоопасности сжиженного природного газа

Excess explosion pressure is one of the main indicators characterizing the explosiveness of a gas. Precise determination of the dependence of the explosion pressure on the distance allows to ensure the safe layout of production facilities with minimal economic costs. Every year, all over the world and in Russia in particular, there is an increase in energy consumption. There is a shift in the global energy system towards the large-scale use of low-carbon energy sources, which is caused by the policy of decarbonization of the fuel and energy complex as part of the fight against global warming. The advantage of operating natural gas in a liquefied state led to the development of the liquefied natural gas market in Russia, with the development of which the risk of accidents at the facilities in this segment of the economy increases. However, the existing methods do not allow calculating the explosion pressure for a mixture of low molecular weight hydrocarbons, which is liquefied natural gas. A new formula for calculating the explosion pressure is proposed considering the composition of the liquefied natural gas. The conducted studies showed the possibility of using the proposed formula to determine the parameters of the explosion of mixtures of low molecular weight hydrocarbons, in particular, liquefied natural gas. It is shown that, despite the linear dependence of the change in the maximum explosion pressure of methane on the change in the percentage of impurities of its homologues, the expected composition of the mixture components differs from that calculated according to the Le Chatelier rule, which can be taken into account in further studies. A comparative analysis of the explosion pressure according to the proposed methodology and the standard showed deviations for grades V, B, and A were 34.99; 20.45; and 2.1%, respectively, which significantly reduces the possible consequences of the explosion and creates a significant error in determining the safe distance. In order to exclude the possibility of obtaining underestimated indicators of the explosion pressure of the liquefied natural gas, it is recommended to use an adjusted methodology.

ANALISIS TATA LETAK ALAT PRODUKSI BUKU TAHUNAN MENGGUNAKAN SYSTEMATIC LAYOUT PLANNING (SLP) DAN BLOCPLAN (STUDI KASUS: CV RENJANA OFFSET)

ANALISIS TATA LETAK ALAT PRODUKSI BUKU TAHUNAN MENGGUNAKAN SYSTEMATIC LAYOUT PLANNING (SLP) DAN BLOCPLAN (STUDI KASUS: CV RENJANA OFFSET)

Production Facility Layout Redesign Using Systematic Layout Planning And Blocplan Methods

Layout of production facilities in CV. Jaya Rubber Industry was identified as less than optimal. The placement of production facilities that are less than optimal causes the distance between several departments to be far apart, for example in the cutting section to the molding section, the molding section to the trimming section and also the QC and packing sections to the finished goods warehouse. It was also found that intersecting material flows can cause backtracking, for example between molding to trimming and packing to the finished goods warehouse. These problems can result in the production process being less effective and efficient. This research combines two methods, namely systematic layout planning and blocplan methods. The systematic layout planning and Blocplan methods have several stages in planning the layout. This method is believed to be able to solve various problems that exist within the company such as production flow, transportation, warehousing, assembly and others. This method was chosen because the current industrial conditions require adjustments in the preparation of a good layout. The results of this study obtained a layout from the blocplan method which was chosen as the proposed layout with a total displacement distance of 44.25 with a decrease in distance of 23.75 m from the initial distance, with an efficiency level of 34% which was able to improve the flow of the production process for the better.

PENERAPAN LAYOUT DENGAN METODE SYSTEMATIC LAYOUT PLANNING DALAM MENINGKATKAN KELANCARAN PRODUKSI PADA UD.TEMON RAYA KABUPATEN PACITAN

The purpose of this research is to determine the layout of the production facilities implemented by UD Temon Raya Pacitan Regency, and then Relayout is performed using the Systematic Layout Planning (SLP) method. This study employs descriptive quantitative methods or descriptive survey research, with data obtained through observations, documentation, and interviews with parties who understand the data required. Based on the results of UD's initial Layout effectiveness test. Temon Raya has a 29.9 % application effectiveness value, with a daily production capacity of 200 pcs and 11 main work stations. While the layout of the design results using the Systematic Layout Planning method has an application effectiveness value of 45.45 %, with the same production capacity and number of work stations, the redesign of the layout of production facilities using the Systematic Layout Planning (SLP) method will be able to improve the smoothness of the process. As a result, the layout design created using the Systematic Layout Planning (SLP) method can be used as a starting point for redesigning the layout of UD's manufacturing facilities. Pacitan Raya Regency Temon Raya

Perancangan Ulang Tata Letak Fasilitas Produksi Menggunakan Metode Fraktal di Manufaktur Spare Part

The relayout of the production facilities needs to be carried out by a manufacturer if there is a new product produced that has a different material flow from the existing product. If the layout of the initial facility is maintained, the material flow will become irregular and lead to long material transfer distances and substantial material handling costs. One method that can be used for relayout production facilities is the fractal method. This method is suitable for job shop system because it could provide a high level of flexibility and low total material handling costs. The case study used in this research, which is a spare part manufacturer that initially applied the by-process layout. The initial layout is less flexible in line with the current manufacturing conditions where there are additional variations in the types of products produced. The distance between machines with different types becomes far apart. By relayout of the production facilities using the fractal method, the material handling cost savings of IDR 157,868.64/week or 60.75%/week and the total savings in moving distance is 186,365 meters/week or 38.93%/week. Fractal method is proven to be used to design the layout of production facilities and reduce material handling costs and material transfer distances.

Re-Layout Tata Letak Bagian Percetakan Menggunakan Calullar Manufacturing System

Material handling in the production division of publisher X encountered several obstacles, including the transfer of material between production processes having cross-movement flows. This condition occurs as a result of an irregular engine layout. The impact of the conditions in the transfer of material in the production process is the distance of the transfer to be 968.6 m/day. This condition causes some machines to be repositioned, so that material transfer can run faster and more efficiently. One of the efforts to reduce material transfer is to re-plan the placement of production facilities by adopting the concept of a cellular manufacturing system or cellular manufacturing system that is feasible to be applied to the production process of publisher X. The cellular manufacturing system was chosen because it is in accordance with the number of characteristics of the publishing industry that requires the ability to anticipate changes. This rapid demand suits a particular market. This article describes how the results of rearranging and minimizing the distance of moving raw materials in the production section of publisher X by adopting the concept of a cellular manufacturing system and rearranging the layout of production facilities by using sorting using Sorting Algorithms. The selection of the Sorting Algorithms is based on consideration of the order of the output which is not coherent, so it needs to be sorted. Efficient sorting is needed to determine the part-machine incidence matrix which is then used in the development of cellular manufacturing systems. Program development on Visual Studio 2012 software shows the results of facility layout planning by grouping 20 machines and 11 products with this layout change, the total material handling distance is reduced by 371.8 m or by 61.61%

Facility Relayout Using Systematic Layout Planning and Blocplan Methods to Minimize Material Handling Distance

. A good facility layout will affect sustaining the smoothness of the production process. initial observation on a current CV. NTY is still not good to apply because it does not take into account the degree of proximity. This can be seen from machine laying as well as workstations that look distanced as well as the flow of intersecting material resulting in backtrackings, such as the blowing department towards the cutting department its material removal distance of 23.2 m and having to go through the packing department and plong department with too much distance and intersect caused the production time to become longer. The methods that production facility layout design uses on the CV. NTY is Systematic Layout Planning and Blocplan methods. This method was chosen because it conforms to the company's characteristics and can minimize the distance between production stations as well as no more intersecting production process flow. This study was conducted to find out and obtain improved material distance efficiency in handling the preliminary layout with the proposed layout. The results of the study show the blocplan method has a total decrease in the displacement distance smaller by 60.73 m with an efficiency increase of 42 % as well as improving the flow of the production process in the initial layout.