Relayout Production Facility Of PC. Spun Pile Using Systematic Layout .
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Relayout Production Facility of PC. Spun Pile UsingSystematic Layout Planning in ABC FactoryMuhammad Ainun Naim1, Erry Rimawan 2, Mahmud3, Adinda Putri4Department of Industrial Engineering1,2, Department of Magister Management3,4Mercu Buana University, Jakarta, IndonesiaAbstract:- ABC Factory is one of the companiesengaged in manufacturing precast concrete inIndonesia. This company was established in 1978 underthe auspices of XYZ Group Since. The productsproduced by ABC Factory are Precast Concrete /Prefabricated Concrete or often abbreviated as "PC".Some of the products manufactured by ABC Factoryare PC. Spun Pile, PC. Square Pile, PC. Spun Pole(Electric Pole), PC. I Girder, PC. Box Girder andseveral other products. ABC Factory uses the Make toOrder production method, so it is demanded to produceorders maximally and as efficiently as possible.In this manufacturing company, the preparation ofthe layout of production facilities greatly affects theproduction cycle time which in turn will have a majoreffect on the company's production capacity. for that,the company needs to redesign the layout of the PCproduction facility of Spun Pile with the best productionflow. Based on these problems, the method used is to usethe SLP (Systematic Layout Planning) method whichfunctions to produce a layout design for productionfacilities that minimizes material movement distanceand produces a good production flow in ABC Factory.Based on the results of the study obtained areduction in the distance of material flow facility layoutby 72.71 meters and an increase in production capacityof 138 cigarettes or 13.44% of the initial layout.Keywords:- Facility Layout Design, Cycle Time, SystematicLayout Planning (SLP).I.INTRODUCTIONABC Factory is one of the companies engaged inmanufacturing precast concrete in Indonesia. This companywas established in 1978 under the auspices of PT.Pembangunan Jaya Group. Since 41 years ago ABCFactory took part in meeting the needs of precast concretein Indonesia.Along with the rapid development in several regionsof Indonesia both projects funded by the government andby foreign parties, making entrepreneurs not hesitate toinvest in manufacturing precast concrete. This was shownby the increasing number of precast concrete companies, sothat competition in the industry of selling precast concreteproducts became tighter. Thus ABC Factory must conductan evaluation of the productivity generated in order to facethe increasingly fierce competition.PC Spun Pile or often called concrete piles is one ofthe superior products owned by ABC Factory and theproduct is also a product that is much needed in everyproject.Fig 1:- Comparison Table of Sadang Factory Production ResultsSeptember - December 2019IJISRT20AUG614www.ijisrt.com1620
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165From the above data it can be seen that the productionof the Sadang PC Spun Pile factory from September December 2019 did not meet the targets given by thecompany. so it needs to be done an analysis ofimprovements to achieve the targets given by the companyin the next period. Where the target given by the companyalways goes up from year to yearProduction layout analysis is carried out based on theresults of the shortest material transfer distance and themost efficient production flow. The purpose of this researchis not only to study various activities, supporting facilitiesand production layout available in the production section ofthe PC Spun Pile product and to be able to recommend anew layout design for the production area related to theoptimization obtained in terms of the distance of materialflow and costs material handling using the SLP (SystematicLayout Planning) method.II.REVIEW OF LITERATUR STUDY Layout FacilityLayout according to Apple (1990), layout is a processof designing and managing physical facilities such asmachinery and equipment, land, buildings and spaces tooptimize the linkages between workers, material flow,information flow and methods needed in order to efficientlyachieve company goals , economical and safe.According to Wignjosoebroto (2009), factory layoutor facility layout can be defined as the procedure formanaging factory facilities to support the smoothproduction process. This arrangement will be useful for thearea of placement of machinery or other supportingproduction facilities, the smooth movement of materialmovements, temporary and permanent material storage,workers' personnel and so onTo analyze the next process. Like the production flowsystem and material handling methods. There are four typesor types of layouts that are classically commonly applied inlayout design, namely:Fig 2:- Facility Layout Based on Production FlowFig 3:- Facility Layout Based on Fixed Material LocationIJISRT20AUG614www.ijisrt.com1621
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Fig 4:- Facility Layout Based on Product GroupsFig 5:- Facility Layout Based on Function or Kind of Process Planning of Production Facility LayoutProduction facility is something that is built, held orinvested to carry out production activities. According toApple (1990, p. 2), "Facility Designers analyze,conceptualize, design and realize systems for themanufacture of goods or services. This design is generallydescribed as a floor plan, namely an arrangement ofphysical facilities (equipment, tana, buildings, and otherfacilities) to optimize the relationship betweenimplementing officers, the flow of goods, information flowand the procedures needed to achieve business objectives ina real, economical and secure." Generally the overall goalof designing a facility is to bring input (materials, supplies,etc.) through each facility in the shortest possible time, at areasonable cost.𝑷𝒕𝒊 𝒎𝒂𝒙 𝑪𝑻 𝑸Explanation:ti max : greatest operating time on the trackCT: cycle time productionP: effective working hours per dayQ: amount of production per day Designing the layout using systematic layout planningmethod.Terdapat 5 elemen untama yang harus diperhatikandalam SLP yaitu : Produk (Produk/P) ; Kuantitas(Quantity/Q); Proses (Routing/R); Sistem/Pendukung(Supporting System/S); dan waktu (Timer/T). Cycle Time of ProductionIs the time required to make one product unit of onestation. If the production time and production targets havebeen determined, then the cycle time can be known fromthe results for the production time and production targets.Systematic Layout Planning is a method used toproduce a facility layout design with the most efficient flowof goods. This method puts forward the sequence of workprocesses and the degree of closeness between service unitscontained in the facility to be designed.In designing the balance of the production line for acertain number of production, the cycle time must be equalto or greater than the biggest operating time which is thecause of the bottleneck of bottlenecks) and the cycle timemust also be equal or smaller than the effective workinghours per day divided by the number of production per day, which is mathematically stated as followsThe stages of the layout design process can bedescribed following the sequence of activities developed byRichard Muther, namely through an approach known asSystematic Layout Planning (SLP).IJISRT20AUG614There are 5 main elements that must be considered inthe SLP, namely: Products (Products / P); Quantity(Quantity / Q); Process (Routing / R); System / Support(Supporting System / S); and time (Timer / T).www.ijisrt.com1622
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Fig 6:- Research literature with the Systematic Layout Planning (SLP) methodIII.METHODOLOGYThe research began with an initial study at ABC Factory regarding company background and literature study based on thefacility layout literature. After that, an observation of the environment and company production facilities is carried out.observations in the production system are based on theories regarding facility layout and material handling and identify existingproduction layouts. Until the end, problems were encountered at the PC Spun Pile production facility at ABC Factory.In this study the analyst used the Systematic Layout Planning (SLP) method. This method analyzes the relationship betweenactivities at each work station. As well as observing the placement of production machines and the number of productionmachines, this is related to the flow of materials during the production process. As well as the area available in existing conditionsand possible space area which can be used as an alternative to the redesign of the layout of the PC Spun Pile production facility.After that, several alternative layout facilities will be made to be analyzed and determined the best option.IJISRT20AUG614www.ijisrt.com1623
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Fig 7:- Research Steps DiagramsIV.RESULT Analysis of Work Flow ProcessIn the preparation of improving the layout of the PC Spun Pile production facility, there are several steps that must beimplemented and described. To produce a good layout, the first step to improve the layout of the Spun Pile PC production facilityis by processing data.At the existing work station there are alternating production flows so that it interferes with the work process at other workstations. That was caused by the factor of material handling and safety methods applied to the PC Spun Pile production process.The handling method is carried out using Over Head Crane (OHC), which when operating will pass through other work stationsand also takes into account the burden of goods being lifted weighing 2-7 tons.Fig 8:- Flow of production of Initial Condition Layout.IJISRT20AUG614www.ijisrt.com1624
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Explanation :1. Warehouse of Iron2. Work Station of Cutting and Heading Process3. Work Station of Forming Process4. Work Station of Setting Process (Setting 2)5. Work Station of Pencil Shoe Production6. Work Station of Concrete Mixxing Process7. Work Station of Concrete Placing Process8. Work Station of Tension Process9. Work Station of Spinning Process10. Work Station of Drying using Steam Boiler11. Work Station of Setting Process (Setting 1)12. Work Station of Demolding Process13. Stock AreaIn the layout of the existing PC Spun Pile productionfacility above, it can be seen that the production flow isdominated by only one line, resulting in overworking ofheavy equipment to lift equipment and affecting the smoothproduction process at the production facility.After direct observation and work time measurementsat each work station, get the average cycle time as follows:Table 1:- Table of Cycle Time PC. Spun Pile ProductionIn the production process of PC Spun Pile piles there are several work processes that can be carried out in conjunction withother work processes, the work process is the Making of Pencil Shoes (no. 5) and Mixing Concrete Materials (no. 6). So the timeneeded to produce one PC Spun Pile is 30.67 minutes. Activity Relation Chart (ARC)From the observations on the work flow at the PC Spun Pile pile production facility and the information from the DeputyProduction department, the ARC diagram is obtained as follows:Table 2:- Activity Relationship Chart (ARC) PC. Spun Pile pile production process Purposed Condition.IJISRT20AUG614www.ijisrt.com1625
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165 Design of Production Facility LayoutIn making the proposed layout / layout the main objective is the smooth flow of work / flow from one work station to anotherwork station. In re-designing the layout of the PC. Spun Pile pile production facility layout, the production facility layout wasused at the ABC Factory plant in Tangerang. Where the plant is felt to be the most productive among the factories / otherproduction plants. The layout of the Tangerang factory / plant production can be seen in the picture. 4.21 follows:Fig 9:- Production Facility Layout of PC. Spun Pile in Tangerang Factory.After observing the production flow and the arrangement of the existing work stations at ABC Factory factory / plantTangerang, a redesign of the production layout at the factory / sadang plant was adopted by slightly adopting the main productionflow and making improvements at several work stations. The following is the draft layout of the proposed PC Spun Pileproduction facility that has been made:Fig 10:- Production Facility Layout of PC. Spun Pile in Sadang Factory (Propous Condition).IJISRT20AUG614www.ijisrt.com1626
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165The picture above is a layout design of PT. Jaya Beton Indonesia plant Sadang conditions of the proposed results of theadoption of the plant layout of ABC Factory Tangerang. In addition to adopting a form of production flow, improvements alsooccurred in work systems at several work stations.Fig 11:- Production Flow of PC. Spun Pile in Sadang Factory (Purpous Condition). Distance of Material HandlingMaterial transfer data is needed to determine the efficiency of distance transfer / material handling between the initialcondition layout and the proposed conditions. The following is the material transfer data from the analysis that has been done:NoFromToDistance(meter)FrequencyTotal Distance(meter)1Warehous Of IroneW.S. Cutting & Heading221222W.S. Cutting & HeadingW.S. Forming6.6516.653W.S. FormingW.S. Setting 16.216.24W.S. Setting 142.55142.555W.S. Pencil Shoe ProductionW.S. Setting 2W.S.Setting 257.55157.556W.S. Setting 2W.S. Tension & Concrete Placing36.94136.947W.S. Tension ProcessW.S.Spinning13.71113.718W.S. SpinningW.S.Drying7.6817.689W.S. DryingW.S.Demolding26.89126.8910W.S. DemoldingStock Area18.75118.75TotalTable 3:- Table distance of material handling initial condition.IJISRT20AUG614www.ijisrt.com238.921627
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Table 4:- Table distance of material handling puspose conditionFrom the above data there is a deviation in thedistance of material handling between the layout of theinitial conditions and the usual conditions. This deviationaffects the duration of changes in the production process.Deviations that occur can be searched by the followingformula:Deviation of DistanceMaterial Handling Initial Distance Purpous Distance 238,92 meter – 166,21 meter 72,71 meterThe deviation causes a change in the production cycletime in the proposed layout. Cycle Time deviation can befound using the following formula:Cycle Time Deviation Deviation of Material Handling (meter)Speed of 𝑂𝑣𝑒𝑟 𝐻𝑒𝑎𝑑 𝐶𝑟𝑎𝑛𝑒 71 meter 20 meter/ minute 3.63 minute Result of Cycle Time Purpous ConditionBased on the degree of closeness between workstations in the Operation Process Chart (OPC) and thearrangement of work stations in PC production facilities.Spun Pile proposed conditions, obtained cycle time at eachwork station as follows :Table 5:- Table of Cycle Time the Purpous Condition.In the production process of PC Spun Pile piles there are several work processes that can be carried out in conjunction withother work processes, the work process is the Making of Pencil Shoes (no. 5) and Mixing Concrete Materials (no. 6). So theproduction cycle time needed to produce one PC Spun Pile pile is 27,035 minutes. Based on the cycle time produced from thelayout of the proposed production capacity of PT. Jaya Beton Indonesia becomesIJISRT20AUG614www.ijisrt.com1628
Volume 5, Issue 8, August – 2020International Journal of Innovative Science and Research TechnologyISSN No:-2456-2165Production Capacity Total Working Hours (minute/bulan)minute)pcs𝐶𝑦𝑐𝑙𝑒 𝑇𝑖𝑚𝑒 of production (31.500 minute27,035 minute/pcs 1.165 pcs/month Comparison and Difference between Initial and Proposed LayoutAfter analyzing the initial layout and designing the proposed layout improvements, several comparisons were obtained. Thefollowing table 5.1 shows a comparison covering several things between the initial layout and the proposal.No1234DescriptionInitial LayoutUsual LayoutThere is alternating flow in some workCircular production flow andProduction Flowprocesses and mold circulation is hamperedcirculation of the story goes wellby over head crane (OHC) activity densityNumber of Work Stations13 Work Station12 Work StationCycle Timeof Production30.67 Minute/Pcs27,035 Minute/PcProduction Capacity1.027 Pcs/month1.165 Pcs/MonthTable 6:- Table Comparation of Initial and Usual ConditionV.CONCLUSIONBased on research conducted on the redesign of thelayout of the PC Spun Pile production facility at ABCFactory, the following conclusions are obtained: With research using the Systematic Layout Planning(SLP) method to make improvements to the layout ofthe existing production facility layout, the layout designis better than the previous condition. Improvementsoccurred in the composition of the work stations whichresulted in smoother production flow. In the layoutdesign layout the production flow forms a "U" flowpattern and makes the PC Spun Pile molding circulatingsmoother. Improvements were also made to theefficiency of the work stations, where in the initiallayout there were 13 work stations and after repairs thenumber of work stations changed to 12 work stations. From the results of data processing and analysis, it isknown that the production cycle time in the proposedlayout is 27.035 minutes / stem or decreased by 11.85%from the previous production cycle time of 30.67 min /stem. And the production capacity of the productioncapacity produced by the proposed layout can reach1,165 cigarettes / month or an increase of 13.44% fromthe previous production capacity of only 1,027cigarettes / month.REFERENCES[1]. Ali Naqvi, S. A., Fahad, M., Atir, M., Zubair, M., &Shehzad, M. M. (2016). Productivity improvement ofa manufacturing facility using systematic org/10.1080/23311916.2016.1207296[2]. Hartiwo, Y. M., & Rimawan, E. (n.d.). PerancanganSimulasi Lacak Balak / Chain of Custody MaterialPulp Dengan Skema Coc – Fsc Di Industri Kertas :Study Kasus Ikpp Tangerang Mill. XI(3), 300–314.[3]. Hermawan, D. (n.d.). Peningkatan ProduktifitasKompor Gas Satu Tungku Melalui Perbaikan TataLetak Fasilitas Di Pt Xyz. 152–163.IJISRT20AUG614[4]. Hossain, R., Rasel, K., & Talapatra, S. (2014).Increasing Productivity through Facility LayoutImprovement using Systematic Layout PlanningPattern Theory. Global Journal of Researches inEngineering: J General Engineering, 14(7), 71–76.[5]. Ojaghi, Y., Khademi, A., Yusof, N. M., Renani, N. G.,& Hassan, S. A. H. B. S. (2015). Production layoutoptimization for small and medium scale foodindustry. Procedia CIRP, 26(December), .050[6]. Pangestika, J. W., Handayani, N., & Kholil, M.(2016). Usulan Re-Layout Tata Letak FasilitasProduksi Dengan Menggunakan Metode Slp DiDepartemen Produksi Bagian Ot Cair Pada Pt Ikp.Jisi : Jurnal Integrasi Sistem Industri, 3(1), 29–38.[7]. S. B. P. (2014). Productivity Improvement in Plant ByUsing Systematic Layout Planning (Slp) - a CaseStudy of Medium Scale Industry. International Journalof Research in Engineering and Technology, 03(04),770–775. https://doi.org/10.15623/ijret.2014.0304136[8]. Safitri, N. D., Ilmi, Z., & Amin, M. (2018). unakan Metode Activity Relationship /10.29264/jmmn.v9i1.2431[9]. Shekhar Tak, C. (2012). Improvement in LayoutDesign using SLP of a small size manufacturing unit:A case study. IOSR Journal of Engineering, 02(10),01–07. https://doi.org/10.9790/3021-021030107[10]. Shewale, P. P., Shete, M. S., & Sane, P. D. S. M.(2012). IMPROVEMENT IN PLANT LAYOUT USINGSYSTEMATIC LAYOUT PLANNING ( SLP ) FORINCREASEDPRODUCTIVITYAddressforCorrespondence. I(Iii), 259–261.[11]. Wiyaratn, W., & Watanapa, A. (2010). Improvementplant layout using systematic layout planning (SLP)for increased productivity. World Academy ofScience, Engineering and Technology, 72(12), 373–377.www.ijisrt.com1629
Systematic Layout Planning is a method used to produce a facility layout design with the most efficient flow of goods. This method puts forward the sequence of work processes and the degree of closeness between service units contained in the facility to be designed. The stages of the layout design process can be
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