2014. Data requirement for layout decisions

11/03/2014

Flow, Space, and Activity Relationship • In determining the requirements of a facility, three important considerations are: – Flow • Depends on lot sizes, unit load sizes, material handling equipment and strategies, layout arrangement, and building configuration

– Space Mata Kuliah: Tata Letak Fasilitas (TKI 4215)

FLOW, SPACE, AND ACTIVITY RELATIONSHIP www.aeunike.lecture.ub.ac.id

• Is a function of lot sizes, storage system, production equipment type and size, layout arrangement, building configuration, housekeeping and organization policies, material handling equipment, and office, cafetaria, and resttoom design

– Activity relatioships • Are defined by material or personal flow, environmental considerations, organizational structure, continous improvement methodology (teamwork activities), control issues, and process requirements

www.aeunike.lecture.ub.ac.id

Data requirement for layout decisions • Frequency of flow of material / some other measure of interaction between departments • Shape and size of departments • Floor space available • Location restrictions for departments, if any • Adjacency requirements between pairs of departments, if any www.aeunike.lecture.ub.ac.id

DEPARTMENTAL PLANNING


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Types of Departments/Layouts

Five types of layout

Volume High

• • • • •

Product Department

Product Layout

Medium Fixed Location Layout Fixed Materials Location Department

Product Family Department Group Technology Layout

Process Layout Process Department

Product layout Process layout Fixed-position layout Group-technology layout Hybrid layout

Low Low

Medium

High

Variety

Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id


Product Layouts

Product layout

Product A Department

D

M

G

P

D

A

L

M

M

D

G

P

A

Product C Department

L

L

G

G

P

Shipping Department

Receiving Department

Product B Department

L

L


D

A


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The Process Layout

Process layout

Milling Department

Lathe Department

DM TM

DM

TM

TM

L

L

L

L

L

L

L

L

L

L

VMM

VMM

BM

BM

L

L

L

L

L

L

L

L

D

D

D

M

M

D

D

D

D

G

G

G

G

G

P

Milling Department

G

P Painting Department

Grinding Department

A

A

A

Assembly


Flow of Materials in Process Layouts L

D

Receiving and Shipping


L

M

DM

TM

Lathe Department

Drilling Department

M

Group technology layout

Drilling Department

M

M

D

D

D

D

M

M

D

D

D

D

G

G

G

P

G

G

G

P

Grinding Department Receiving and Shipping

Source: Russell & Taylor, 2007 www.aeunike.lecture.ub.ac.id

TM

DM

BM

TM

VMM

TM

DM

BM

Painting Department

A

A

A

VMM

DM

TM

Assembly


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A Manufacturing Cell

Product Family (Cellular) Layout G

D D

Rotational Parts Cell

D

L

M

G

D

L

M

D

L

G

L

M

L

G

Rectangular Parts Cell

A

A

HM

L

P

L

G

D

M

P

L

D

Special Department

Paths of three workers moving within cell Material movement Key: S L HM VM G

= Saw = Lathe = Horizontal milling machine = Vertical milling machine = Grinder


Direction of part movement within cell

G L

VM Worker 3

VM

L

Worker 2

G

L Final inspection

S

Worker 1

Finished part

Out

In Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id


Project (Fixed-Position) Layout G

G

D

D

D

L

G

L

A M

TM

TM

TM

TM

VMM

Storage

Storage

G

L L

Hybrid layout

BM

DM

A

P




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General Characteristics

Hybrid Layouts • Combination of the layouts discussed. • A combination of group layout in manufacturing cells, product layout in assembly area, and process layout in the general machining and finishing section is used. TM

DM

TM

TM

BM

TM

TM

Product

Process

Product Family

Project

Throughput Time

Low

High

Low

Medium

Work in process

Low

High

Low

Medium

Choice

High

Med-High

Mixed

Product Flexibility

Low

High

Med-High

High

Demand Flexibility

Medium

High

Medium

Medium

Mach Utilization

High

Med-Low

Medium-High

Medium

Worker Utilization

High

High

High

Medium

Can be low

High

High

Medium

Low

High

Low

High

Characteristic

Skill Level

Reliability Unit production cost



Exercise – What Type of Layout?

Automated Manufacturing Cell

• Ford Louisville Assembly Plant

___________

• Suburban Hospital

___________

• Louisville International Airport

___________

• KFC Restaurant

___________

• Boeing Aircraft

___________



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Flexible Manufacturing Systems

Flow diagram 2

1

3

MEJA MEJA

PENYIMPANAN ALAT

3

6

4

3

MESIN BOR

MESIN BOR 2

7

ASSEMBLING

PEMANGGANG

9

12

PAINTING

Peluncur Bahan

6

13

7

11

18 8

14

9

10

5

17

Peluncur Bahan

PENGEMASAN

16 15

Peluncur Bahan

4

Peluncur Bahan

Peluncur Bahan 12

MEJA PERAKITAN

8

6

GUDANG

FINISHING

7

20

5

3

Peluncur Bahan

11

6

13

Peluncur Bahan

PENGIRIMAN

Peluncur Bahan

18

8


2

MESIN BUBUT

1

Peluncur Bahan

1

MESIN FRAIS

PENERIMAAN

DIAGRAM ALIR (FLOW DIAGRAM)

5

 Automated machining operations, tool changers  Automated material handling, computer control  Designed around size of parts processed & average processing time for parts  Can process wide variety of items quickly  Very few large systems exist • Progressive layout – all parts same route • Closed loop – larger variety, alternative routes • Ladder layout – two machines work on same part • Open field layout – most complex


Flow pattern at 800-acre Nissan plant in Smyrna, TN (1989)

FLOW PATTERN



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Flow Between Departments: Straight Line atau pola aliran lurus ( I Flow)

Flow Within Departments:

O-1

O-2

O-3

O-4

O-5

Proses yang berlangsung singkat Proses produksinya relatif sederhana Item tunggal/sedikit, jumlah produksi yang besar. Pola aliran bahan ini akan memberikan : – Jarak perpindahan yang pendek antar proses. – Proses berlangsung lurus sesuai urutan mesin • Jarak perpindahan bahan total akan kecil • • • •

(a). End-to-end; (b). Back-to-back; (c). Front-to-front; (d). Circular; (e). Odd angle www.aeunike.lecture.ub.ac.id

Flow Between Departments: Pola aliran menyerupai huruf “U” (U Flow)

Flow Between Departments: Serpentine atau zig-zag (S Flow)

O-1

O-4

O-5

O-2

O-3

O-6

(A)

O-1

O-2

O-4

O-3

O-5

O-6

(B)

Pola aliran seperti huruf “S” diatas sangat baik diterapkan bilamana aliran proses produksi lebih panjang dibandingkan dengan panjang area yang tersedia. Untuk itu aliran bahan dibelokkan untuk mengurangi panjangnya garis aliran yang ada.

O-6

O-5

O-4

O-1

O-2

O-3

Pola aliran ini dipakai bilamana dikehendaki akhir dari proses produksi akan berada pada lokasi yang sama dengan awal proses produksi. Hal ini meningkatkan pemanfaatan fasilitas transportasi dan mudah untuk mengawasi keluar masuknya material dan produk jadi. Aliran perpindahan bahan relatif panjang .

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Flow Between Departments: Circular (O Flow)

Flow Between Departments: ODD angle O-2

O-3 O-2

O-4

O-3 O-1

O-1

O-6

O-5

O-4

O-6 O-5

Pola aliran circular ini sangat baik diterapkan pada proses yang mengkehendaki pengembalian material atau produk jadi pada titik awal produksi. Pola ini juga dapat diterapkan pada proses yang menempatkan proses penerimaan bahan/material dan pengiriman barang jadi pada area yang sama.

POLA ALIRAN MENURUT KELUAR-MASUK BAHAN

• Tujuannya adalah untuk memperoleh garis aliran produk melewati suatu kelompok kerja dari area yang saling berkaitan. • Proses perpindahan bahan (Material handling) secara mekanik. • Terbatasnya ruang dan dikehendaki adanya pola aliran yang tetap

POLA ALIRAN MENURUT KELUAR-MASUK BAHAN

ON THE SAME SIDE BUT AT OPPOSITE ENDS AT THE SAME LOCATION

ON OPPOSITE SIDES ON ADJACENT SLIDES

ON THE SAME SIDE BUT AT OPPOSITE ENDS

AT THE SAME LOCATION

ON OPPOSITE SIDES

ON ADJACENT SLIDES

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11/03/2014

MACAM POLA ALIRAN YANG BERSILANGAN

A

B

C

D

E

F

G

H

UNINTERRUPTED FLOW PATHS

A

F

C

H

E

B

D

G

POLA ALIRAN BAHAN UNTUK PROSES PERAKITAN (ASSEMBLY)

INTERRUPTED FLOW PATHS

Pola aliran bahan untuk proses perakitan: Combination Assembly Line Patern

Pola aliran bahan untuk proses perakitan: Tree Assembly Line / Spine Flow Patern

Pada pola aliran ini main assembly line akan disupplai dari sejumlah sub-assembly atau part line. Sub-assembly berada pada sisi yang sama.

Sub-assembly line akan berada pada kedua sisi dari aliran main assembly. Biasanya pada penerapan pola aliran ini, main assembly akan berada ditengah bagian pabrik.

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Pola aliran bahan untuk proses perakitan: Dendretic Assembly Line Patern

Pola aliran bahan untuk proses perakitan: Overhead Assembly Line Patern

2nd Floor

1st Floor

Pola ini akan lebih tidak teratur dibanding dengan pola aliran sebelumnya. Pada pola aliran ini, setiap bagian berlangsung operasi sepanjang lintasan produksi, menuju proses produksi yang lengkap untuk proses assembling.

Pola aliran ini merupakan model pola aliran untuk lantai produksi yang lebih dari satu lantai.

Flow planning hierarchy

FLOW PLANNING



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A. STRING DIAGRAM String Diagram merupakan alat untuk menggambarkan aliran bahan/material dalam layout, dengan menggunakan tali, benang, kawat, dan sebagainya.

Flow Measurement

OTahapan pembuatan : • Tusukkan paku, baut atau jarum pentul pada fasilitas-

fasilitas dalam layout (pada titik proses dimulai atau berhenti)

• Hubungkan paku atau jarum yang telah dipasang

sesuai dengan keterkaitan proses atau alur proses.

• Gunakan penghubung antar paku/titik menggunakan

benang, karet, tali yang berwarna-warni

PENGOLAHAN LIMBAH 1

6

B. FROM TO CHART O Dikenal juga sebagai Travel Chart O Suatu teknik konvensional yang umum

12

7

13

3 4 2

W/H FINISH GOOD

W/H MATERIAL 5

10 11

8

9

digunakan untuk perencanaan tata letak pabrik dan pemindahan bahan dalam suatu proses produksi. O Sangat berguna dalam menganalisa aliran bahan pada proses dengan banyak item yang mengalir melalui suatu area. O Teknik ini akan menunjukkan total berat beban yang harus dipindahkan, jarak perpindahan dan volume perpindahan

Kemungkinan terjadinya kemacetan aliran

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LANGKAH PENYELESAIAN

DIMENSI DEPARTEMEN

O Kumpulkan data “Volume of Handling”, luas

area/departemen & alur proses produksi tiap produk PRODUK

VOLUME OF HANDLING

% VOLUME OF HANDLING

ALUR PROSES

P1

2000 Kg

20

P2

2000 Kg

P3

2500 Kg

P4 P5

5x5

C

8 x 10

20

A-C-D-F-G-I

D

10 x 5

25

A-D-B-E-H-F-I

E

25 x 10

2000 Kg

20

A-C-D-B-E-G-I

F

5x5

500 Kg

5

A-E-F-G-H-I

G

5 x 10

P6

500 Kg

5

A-D-C-B-F-G-H_I

H

8x8

P7

500 Kg

5

A-C-D-H-D-G-I

I

16 x 16

A

B

C

D

KONDISI AWAL

5

25+2 0

FROM

E

F

G

H

A B

20

C

20+20+ 5

D

25+5

E

5

F

20

5 20+20+20+5

25+20 5

G H I

10 x 10

A-B-C-D-E-F-G-H-I

untuk sementara dianggap sama)

TO

DIMENSI (meter )

A

B

O Buatlah from to chart berdasarkan % volume handling (jarak FROM

DEPARTEMEN

Perpindahan P1 dari A ke B Sebesar 20

5 20 20

20+ 5

5

20

5

25

25 20+20+5+5

I

TO

A

B

C

D

5

45

E

F

G

H

J

A

0

B

20

C

45

D

30

E

5

20

70

5

70

65

5

45

20

5

20

25

G

5

20

H

5

25

F

100 70

J

25

75

50

75 30

25

45

60 30

100

20+5+5 25

20+20+5

20+5+ 5

100

70

70

100

70

75

75

60

0

620

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11/03/2014

Volume Aliran Dari Jarak Diagonal FORWARD Jarak dari diagonal

BACKWARD Koefisien Jarak

Moment

Moment

Jarak dari diagonal

(10 x 1)

(5+5)

• Pada From to Chart diketahui adanya Back

Tracking sebesar 15% dari total aliran bahan (ditandai dengan warna merah).

(20+20+65+20+25+50+30+ 30)

(260 x 1)

=10

=10

(70 x 2)

(45+25)

2

=140

=70

3

0

0

= 260

= 260

(45+20+20+45)

(130 x 2)

=130

= 260

(30+45+5+25+25)

(130 x 3)

=130

= 390

(5+5+5)

(15 x 4)

=15

= 60

4

=20

5

0

0

5

0

0

0

0

6

0

0

970

1140

170

1

• Semakin kecil back tracking akan semakin baik • Sehingga diperlukan evaluasi aliran proses yang

mengalami back tracking, dalam kasus diatas adalah pada produk P3 dengan aliran awal A-DB-E-H-F-I • Kemudian dilakukan perubahan terhadap aliran P3 menjadi A-B-D-E-F-H-I • Besarnya perubahan terhadap aliran P3 dapat dilihat pada tahap berikut ini.

(5 x 4)

85%

15%

Kondisi setelah perubahan aliran A-B-D-E-F-H-I FROM TO

A

B

C

D

E

F

G

KONDISI PERBAIKAN FROM

H

B

20+25

C

20+20+ 5 20

5

B

C

D

5

20

B

45

C

45

20

D

5

25

E

5

20

45

5

20+20+20 +5

25

E

5

20

20+2 5

5

20

I

A

5

5

G

TO

20

D

H

I

E

F

G

H

I

A

A

F

BACK TRACKING

5

5 5

F

20+5+2 5 20

20+20+5+ 5 25

20+5+5 20+20+ 20+5+5+2 5 5

5 65

5

20

50

G

5

20

H

5

I

50 25

30 45

55

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11/03/2014

Volume Aliran Dari Jarak Diagonal FRWD

C. ACTIVITY RELATIONSHIP CHART

BCWD

Jarak dari diagonal

Moment

Koefisien Jarak

Jarak dari diagonal

Moment

360

360

1

10

10

180

360

2

40

20

30

90

3

0

0

15

60

4

20

5

0

0

5

0

0

0

0

6

0

0

0

0

7

0

0

0

0

8

0

0

870

940

70

93%

Teknik kualitatif yang sederhana dalam merencanakan tata letak fasilitas atau mesin. Berdasarkan derajat hubungan aktivitas dari masing-masing fasilitas atau mesin tersebut. O 1. 2. 3. 4.

Prosedur pembuatan Activity Relationship Chart (ARC) sebagai berikut : Identifikasi semua fasilitas kerja / departemen / mesin Definisikan kriteria hubungan antar fasilitas kerja Tentukan nilai hubungan antar fasilitas Plot hasil perumusan nilai hubungan dalam ARC

7%

Kode Derajat Hubungan Antar Fasilitas Line code

Numerical weights

Value

Closeness

A

Absolutely necessary

16

E

Especially important

8

I

Important

4

O

Ordinary closeness OK

2

U

Unimportant

0

X

Undesirable

80

O Percentages of A, E, I, O, U and X ratings O A 2-5% O E 3-10% O I 5-15% O O 10-25% O U 25-60% O X depends O Color coding relationships O A Red O E Orange or Yellow O I Green O O Blue O U Uncolored O X Brown

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11/03/2014

ACTIVITY RELATION CHART Derajat hubungan

1 FASILITAS A

Alasan kedekatan I hubungan 1 O X 3 2

2 FASILITAS B 3 FASILITAS C

1

Lathe (10 x 15)

2

Drill 1(10 x 10)

3

Mill (20 x 20)

4

Punch Press (15 x 15)

5 6 7

Centerless Grinder (15 x 15) Shaper (10 x 20) Planer (10 x 20)

8

Drill 2(10 x 10)

9

Mill 2(15 x 20)

10 CNC Machine (10 x 25) 11 Punch Press 2 (15 x 15) 12 Vertical Turret Lathe (10 x 10)

I

O 4

A 2

1

A

E

3

O

1

A

7

A 5

I

E

5

A

6

2

E

7

E

U 2

O

5

I

5

O

A 5

E

6

U

2

A

3

I

4

U

1

O

5

U

U

4

U

2

E 3

U 3

5

O 7

I

6

E

E

3

X

5

O

9

1

I

5

U

A

9

7

O

U A 2

2

Penggunaan man power sharing

3

Penggunaan space area sharing

4

Tingginya tingkat hubungan personil

5

Keterkaitan pemakaian worksheet

6

Keterkaitan urutan proses kerja

7

Kesamaan proses kerja

8

Penggunaan jig and tools secara bersama

9

Ketidaknyamanan ketika berdekatan

U

O

5

U

7

U

O U

O 1

2

2

4

O

8

4

O

1

X

7

O

1

DESKRIPSI ALASAN KEDEKATAN Penggunaan data hasil proses secara besamaan

I 4

U

7 3

KODE ALASAN

ACTIVITY RELATIONSHIP CHART

A 3

Contoh Alasan Kedekatan Hubungan

4

U 2

1

U

E

6

O

4

I

4

6

X

3

U

9

9

U 8

U

E 3

I

2

8

SPACE REQUIREMENT

1


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11/03/2014

Space Requirements • The most difficult determination in facilities planning • The design year: 5-10 years • Uncertainty –due to impact of technology, Changing product mix, changing demand levels, changing organization designs for the future • Needs a systematic approach: “From the ground up”

– Products are delivered to the points of use in smaller lot and unit load size – Decentralised storage areas – Less inventories (using a pulled system) – Manufacturing cells – Companies are downsizing www.aeunike.lecture.ub.ac.id

Space Requirements

Space Requirements

Workstation Specification (space for equipment, materials, and personnel) • Equipment Space consists of space for

– the equipment; machine travel;machine maintenance; – plant services Materials Space consists of space for

– Receiving and storing materials; In-process materials; – Storing and shipping materials; Storing and shipping waste and scrap; Tools, fixtures, jig, dies, and maintenance materials •

• In manufacturing and office environments, space requirements should be determined first for individual workstations; next, departments, etc. • Modern manufacturing approaches can reduce space requirements.


•

•

Space Requirements

• Department Specification

• Aisle Arrangement • Visual Management and Space Requirement

Personnel area consists of space for

– The operator; Material handling; Operator ingress and egress. www.aeunike.lecture.ub.ac.id


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Space Requirements

Space Requirements

Simple rules of thumb are used to determine the extra space that is required (Heragu, 1997)

  

3 – 4 feet are added to the length and width of each machine or workstation The additional space is calculated as a percentage of the actual area occupied by a workstation, typically 200% to 300% Calculate the space required for the workstation, auxiliary equipment, operator space, incoming material and work in process space, and other additional space (e.g., load and unload acces, material handling carrier clearance) and add the separate quantities to determine the total space required (the preffered method of determining extra space) www.aeunike.lecture.ub.ac.id

Workstation

Aisle Allowance



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Departmental Service

Aisle Widths



Visual Management

•

Visual Management

Keterangan gambar:

A. Identification, housekeeping, and organization 1. 2. 3. 4. 5. 6. 7. 8. 9.

Identification of the department Identification of activities, resources, and products Identification of the team Markings on the floor Markings of tools, racks, fixtures Technical area Communication and rest area Information and instructions Housekeeping tools

B. Visual documentation 10.

Manufacturing instructions and technical procedures area

C. Visual production, maintenance, inventory, and quality control 11. 12. 13. 14. 15. 16. 17.

Computer terminal Production schedule Maintenance schedule Identification of inventories and work-in process Monitoring signals for machines Statistical process control Record of problems

D. Performance measurement 18.

Objectives, result, and difference

E. Progress status 19. 20.


Improvement activities Company project and mission statement


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References • Heragu, S. (2008). Facilities Design (3rd Ed.). CRC Press. • Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley. • Wignjosoebroto, S. (1996). Tata Letak Pabrik dan Pemindahan Bahan. Surabaya: Guna Widya.

19

2014. Data requirement for layout decisions

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