DAFTAR ISI HALAMAN JUDUL .................................................................................. LEMBAR PENGESAHAN ......................................................................... KATA PENGANTAR ................................................................................ DAFTAR ISI .............................................................................................. DAFTAR TABEL ...................................................................................... DAFTAR GAMBAR .................................................................................. ABSTRAK ................................................................................................. BAB I
BAB II
PENDAHULUAN 1.1. Latar Belakang Masalah..................................................... 1.2. Perumusan Masalah ........................................................... 1.3. Batasan Masalah dan Asumsi ............................................. 1.3.1. Batasan masalah ..................................................... 1.3.2. Asumsi ................................................................... 1.4. Tujuan Penelitian ............................................................... 1.5. Manfaat Penelitian ............................................................. 1.6. Sistematika Penulisan ........................................................ LANDASAN TEORI 2.1. Tata Letak Pabrik ............................................................... 2.1.1. Pengertian tata letak pabrik ..................................... 2.1.2. Tujuan perencanaan dan pengaturan tata letak pabrik ..................................................................... 2.2. Langkah-langkah Perencanaan Tata Letak Pabrik .............. 2.3. Tipe Tata Letak Pabrik dalam Sistem Manufaktur .............. 2.4. Pemindahan Bahan (Material Handling) ............................ 2.5. Pola Aliran Pemindahan Bahan .......................................... 2.5.1. Pola aliran bahan untuk proses produksi (fabrikasi) .............................................................. 2.5.1. Pola aliran bahan untuk proses perakitan (assembly) ............................................................. 2.6. Pengukuran Jarak ............................................................... 2.6.1. Rectilinear distance ................................................ 2.6.2. Euclidean distance.................................................. 2.6.3. Squared euclidean distance .................................... 2.6.4. Aisle ....................................................................... 2.7. Ongkos Material Handling (OMH) .................................... 2.8. Algoritma CRAFT ............................................................. 2.9. WinQSB ............................................................................ 2.9.1. Penentuan baris dan kolom dalam WinQSB ............ 2.9.2. Metode penyelesaian masalah ................................. 2.9.3. Langkah-langkah pengoperasian WinQSB 2.0 ........
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i ii iii v viii ix x
I-1 I-3 I-3 I-3 I-3 I-4 I-4 I-4
II-1 II-1 II-2 II-6 II-7 II-13 II-14 II-15 II-18 II-21 II-21 II-22 II-23 II-24 II-25 II-26 II-34 II-36 II-37 II-37
BAB III METODOLOGI PENELITIAN 3.1. Obyek Penelitian................................................................ 3.2. Pengumpulan Data ............................................................. 3.3. Data yang dibutuhkan ........................................................ 3.4. Kerangka Penelitian ........................................................... 3.5. Pengolahan Data ................................................................ 3.6. Analisis Hasil..................................................................... 3.7. Kesimpulan dan Saran ....................................................... BAB IV PENGOLAHAN DATA DAN ANALISIS HASIL 4.1. Pengumpulan Data ............................................................. 4.1.1. Layout awal lantai produksi .................................... 4.1.2. Luas area lantai produksi dan masing-masing departemen ............................................................. 4.1.3. Titik koordinat masing-masing departemen ............ 4.1.4. Titik koordinat pusat (centroid) masing-masing departemen ............................................................. 4.1.5. Urutan proses produksi ........................................... 4.1.6. Aliran bahan ........................................................... 4.1.7. Gaji operator........................................................... 4.2. Pengolahan Data ................................................................ 4.2.1. Jarak rectilinear antar departemen pada layout awal........................................................................ 4.2.2. Jarak material handling pada layout awal ............... 4.2.3. Ongkos material handling (OMH/m) ...................... 4.2.4. Biaya material handling pada layout awal .............. 4.2.5. Perhitungan Algoritma CRAFT dengan software WinQSB 2.0 ........................................................... 4.2.6. Menganalisa output dari software WinQSB 2.0....... 4.2.7. Tata letak lantai produksi setelah perbaikan ............ 4.2.8. Titik koordinat masing-masing departemen pada layout usulan .......................................................... 4.2.9. Titik koordinat pusat (centroid) masing-masing departemen pada layout usulan ............................... 4.2.10. Jarak rectilinear antar departemen pada layout usulan ..................................................................... 4.2.11. Jarak material handling pada layout usulan ............ 4.2.12. Biaya material handling pada layout usulan............ 4.2.13. Menghitung efisiensi perubahan ............................. 4.2.14. Menghitung biaya perubahan tata letak fasilitas ...... 4.3. Analisis Hasil..................................................................... 4.3.1. Analisis proses pengambilan keputusan pada software WinQSB 2.0 ............................................. 4.3.2. Analisis penurunan jarak dan biaya material handling .................................................................
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III-1 III-1 III-2 III-4 III-7 III-8 III-9
IV-1 IV-1 IV-3 IV-4 IV-5 IV-6 IV-8 IV-9 IV-9 IV-9 IV-10 IV-11 IV-13 IV-14 IV-15 IV-16 IV-19 IV-20 IV-21 IV-22 IV-23 IV-24 IV-25 IV-25 IV-25 IV-25
BAB V
KESIMPULAN DAN SARAN 5.1. Kesimpulan........................................................................ V-1 5.2. Saran ................................................................................. V-2
DAFTAR PUSTAKA LAMPIRAN
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DAFTAR TABEL Tabel 2.1 Titik koordinat pusat (centroid) setiap departemen pada layout awal ............................................................................... Tabel 2.2 From to chart Ongkos Material Handling (OMH/m) ................. Tabel 2.3 From to chart jarak antar departemen pada layout awal ............. Tabel 2.4 From to chart biaya material handling ...................................... Tabel 2.5 Titik koordinat pusat (centroid) setiap departemen pada iterasi 1 ...................................................................................... Tabel 2.6 From to chart jarak antar departemen pada iterasi 1................... Tabel 2.7 From to chart biaya material handling pada iterasi 1 ................. Tabel 4.1 Luas area departemen produksi dan non-produksi...................... Tabel 4.2 Titik koordinat masing-masing departemen ............................... Tabel 4.3 Titik koordinat pusat (centroid) masing-masing departemen ...... Tabel 4.4 Aliran bahan pada lantai produksi sarung tangan golf ................ Tabel 4.5 Jarak rectilinear antar departemen pada layout awal .................. Tabel 4.6 Jarak material handling pada layout awal .................................. Tabel 4.7 Biaya material handling pada layout awal lantai produksi ......... Tabel 4.8 Initial layout in cell location ...................................................... Tabel 4.9 From to chart biaya pemindahan bahan ..................................... Tabel 4.10 Output software WinQSB 2.0 untuk layout lantai produksi perusahaan................................................................................. Tabel 4.11 Titik koordinat masing-masing departemen pada layout usulan ........................................................................................ Tabel 4.12 Titik koordinat pusat (centroid) masing-masing departemen pada layout usulan ..................................................................... Tabel 4.13 Jarak rectilinear antar departemen pada layout usulan ............... Tabel 4.14 Jarak material handling pada layout usulan ............................... Tabel 4.15 Biaya material handling pada layout usulan lantai produksi....... Tabel 4.16 Efisiensi perubahan ................................................................... Tabel 4.17 Biaya perubahan tata letak fasilitas ............................................
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II-30 II-30 II-31 II-31 II-32 II-33 II-34 IV-3 IV-5 IV-6 IV-8 IV-10 IV-11 IV-13 IV-14 IV-15 IV-15 IV-20 IV-21 IV-22 IV-23 IV-24 IV-24 IV-25
DAFTAR GAMBAR Gambar 2.1 Product layout ......................................................................... Gambar 2.2 Process layout ......................................................................... Gambar 2.3 Fixed layout ............................................................................ Gambar 2.4 Group technology layout ........................................................... Gambar 2.5 Siklus aliran bahan dalam sebuah pabrik ................................ Gambar 2.6 Pola aliran straight line .......................................................... Gambar 2.7 Pola aliran serpentine atau zig-zag (s-shaped) ........................ Gambar 2.8 Pola aliran u-shape................................................................. Gambar 2.9 Pola aliran circular ................................................................ Gambar 2.10 Pola aliran odd-angle ............................................................. Gambar 2.11 Pola aliran combination assembly line pattern........................ Gambar 2.12 Pola aliran tree assembly line pattern ..................................... Gambar 2.13 Pola aliran dendretic assembly line pattern ............................ Gambar 2.14 Pola aliran overhead assembly line pattern............................. Gambar 2.15 Jarak euclidean ...................................................................... Gambar 2.16 Jarak euclidean ...................................................................... Gambar 2.17 Jarak aisle .............................................................................. Gambar 2.18 Layout awal pada koordinat x dan y........................................ Gambar 2.19 Layout iterasi 1 pada koordinat x dan y ............................ Gambar 2.20 Tampilan awal modul Facility Location and Layout............... Gambar 2.21 Tampilan spesifikasi masalah yang akan diselesaikan ............ Gambar 2.22 Tampilan lembar kerja untuk memasukkan data ..................... Gambar 2.23 Tampilan metode penyelesaian .............................................. Gambar 3.1 Kerangka penelitian ............................................................... Gambar 3.2 Kerangka penelitian (lanjutan) ............................................... Gambar 3.3 Algoritma CRAFT ................................................................. Gambar 4.1 Layout awal lantai produksi PT Adi Satria Abadi ................... Gambar 4.2 Layout awal lantai produksi pada koordinat x dan y................ Gambar 4.3 Peta proses operasi pembuatan sarung tangan golf ................. Gambar 4.4 Output dari software WinQSB 2.0 untuk layout usulan lantai produksi ....................................................................... Gambar 4.5 Layout usulan lantai produksi PT Adi Satria Abadi ................ Gambar 4.6 Layout usulan lantai produksi pada koordinat x dan y .............
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II-7 II-9 II-11 II-13 II-14 II-15 II-16 II-16 II-17 II-18 II-19 II-19 II-20 II-20 II-22 II-23 II-24 II-29 II-32 II-38 II-38 II-39 II-40 III-4 III-5 III-6 IV-2 IV-4 IV-7 IV-16 IV-18 IV-19
