D&N CONSULTING

Project Team:
Davis Belmiro Satria (1606886236)
Nara Adhistana (1606906383)

Jl. Gatot Subroto No.Kav. 9-11, RT.2/RW.4, Karet Semanggi, Kecamatan Setiabudi, Kota Jakarta
Selatan, Daerah Khusus Ibukota Jakarta 12930

Table of Contents
1. Chapter 1: Proposal Tender
2. Chapter 2: Literature Study
2.1. Area of the machine calculation
2.2. Area of the factory calculation
2.3. Warehouse Area Calculation
2.4. Office and supporting area calculation
2.5. Area Allocation Diagram (AAD)
3. Chapter 3: Data Processing
3.1. Area of the machine calculation
3.2. Area of the factory calculation
3.3. Warehouse Area Calculation
3.4. Office and supporting area calculation
3.5. Area Allocation Diagram (AAD)
4. Chapter 4: Analysis
5. Chapter 5: Conclusion
6. References

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Chapter 1: Tender Proposal
1.1. Overview

Factory layout can be defined as the procedure for regulating factory facilities to support
the smooth production process (Wignjsoebroto, 1996). the arrangement utilizes the vast space for
the placement of machines, production facilities, the smooth flow of material, storage of material
whether temporary or permanent. We the “D&N Consulting” company or also called “Davis &
Nara Consulting” The company is based in Indonesia and was founded 22 years ago in 1996. The
company provides its service worldwide. Its headquarters is located in Jakarta with 127 offices
spread across the world. We also has a network of more than 27,000 employees.
We follows a strict culture of work and ethics with highly motivated and zealous
employees. The company values traits like loyalty, integrity, and dynamism.

1.2. Objective

Our main objective is to maximize production at minimum cost, by arranging the workers
and equipment in certain position to reach the most ideal position to achieve the best outputs of
production.

1.3. Design Procedure

Step 1 : Tender Proposal
Step 2 :Product Design
● exploded assembly drawing
● exploded assembly photograph
● Component Part Drawing
Step 3 :Process Design ( Identification)
● Parts List
● Bills of material
Step 4 :Process Design (Selection)
● Route sheet

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 Step 5 :Process Design ( Sequencing)
● Assembly chart
● Operation Chart
● Precedence Diagram
Step 6 :Schedule Design
● Quantity if the product
● Equipment requirements
● Operator requirements
Step 7:Activity Relationship Chart (ARC) and Activity Relationship Diagram (ARD)
Step 8 : calculation
● Area of the machine calculation
● Area of the factory calculation
● Warehouse Area Calculation
● Office and supporting area calculation
● Area Allocation Diagram (AAD)
Step 9 : Plant Layout Design

1.4. Work Plan

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1.5. Work Schedule

1.6. Closing Statement

That are all the services that we will give if the D&N Consulting accept our tender. We
really hope that The D&N Consulting will colaborate with us and maintain our relation to
the future. Thank you.

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Chapter 2: Literature Study

1. Machine calculation area and factory calculation area

The machine calculation area and factory calculation area are factory layout settings. This stage is done to
find out the number of machines used at each work station or work station and the area needed for each
work station based on the number of machines needed to produce folding ladder products. The area of
​each work station or work station will be made a runway or according to the factory layout plan for
folding ladder products.
In this factory layout procedure, your company is given the task to calculate the area needed for each
work station or work station to produce folding stairs. Calculation of the area of ​each work station or
work station is adjusted to the number of machines that you have calculated on the routing sheet in the lab
report 1.

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2. ​Calculate the entire area of ​each type of work station needed.
In this lab you will design a factory layout based on the process layout and product layout. Therefore
there are two calculations to calculate the area of ​the production floor.
To calculate the total production area based on the process layout, you can use a table with the format as
in Table 4. To calculate the total production area based on product layout, you can use a table with the
format as shown in Table 5.
* Machine size (Length and Width): determined
Area of ​each machine = Machine length x Machine width
* Work table size (Length and Width): determined
Workbench size is the size of a table to work on material (where material and machinery support).
Workbench area = Work table length x Workbench width
* Operator station (Length, Width, and Motion Requirement): specified
Area of ​operator space = Length x Width x Motion Requirement
* Material space before and after:
Process layout: is the largest material size of the entire production process Product layout: adjusted to the
size of each component contained in the lab module 1.
Example: Cutting wood "component 1 (top plank)"
• Material size before (material size before cutting): P = 0.600 m and L = 0.045 m
• Size of material after (size of material after cutting): P = 0.360 m and L = 0.045 m
• If there is no process that changes the size of the material, then:

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Material size before = Size of material after
* Work Station Area (SK)
Area of ​Work Station (SK) = Area size of table + Area of ​Operator Space + Area of ​material space
(before) + Area of ​material (after)
Note: The area of ​the machine is not included in this calculation, because it will be multiplied first by the
number of machines needed in each process. * Allowances (determined by 20%)
Allowances = Work Station Area x Allowances (20%) * Area + Allowances
Area of ​Work Station + Allowances
* Total Production Area
Total Production Area = Total Workstation Area + Allowances
2. Calculation of warehouse area
Calculation of warehouse area is something done in spatial planning
factory location to measure the warehouse area needed. There are three warehouses that will be used in
making folding stairs, namely Raw Material Warehouse (GBB), Finished Material Warehouse (GBJ), and
Scrap Warehouse.
The following is a calculation in making the Raw Material Warehouse (Table 8) and the Finished
Material Warehouse (Table 9).
* For the raw material needed for its size (length, width and height) it has been determined.
* Amount of Receipt
• Normal acceptance is the amount of raw material or material received from the supplier. For GBB, it has
been agreed upon.
For GBJ, according to the production per day of each group according to the practicum module 1.
• Frequency
In the Raw Material Warehouse (GBB) frequency is the inventory material (in units of days), that is
comparison material purchased but not processed. The amount of inventory for each group is different
according to the division in the practicum module 1.
In the Finished Material Warehouse (GBJ) frequency is the product inventory (in units of days). The
amount of inventory for each group is different according to the practicum module 1.
• Security stock, is additional material that is stored for approval or stored that already exists (stock is
depleted) for example because of the use of goods that are greater than the original estimate or delay in
receipt of goods purchased. In this lab the safety stock is set at 10%. The formula for calculating safety
stocks for both GBB and GBJ is as follows:

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Safety stock = 10% x Total Received Normal x Frequency Then the calculation results of the safety stock
are rounded up.
• Maximum inventory, is the maximum amount of material received and must be stored in the warehouse
of raw materials. The formula for calculating accepts the maximum for both GBB and GBJ as follows:
Maximum Performance = (Accept Normal x Frequency) + Safety Stock
• The type of transport has been determined. * Moving Unit
• Types of transfer units that have been determined.
• Transfer Unit / Unit for GBB and GBJ obtained by calculation as
following:
Unit / Unit Transfer = (Length of Unit of Transfer Unit / Length of raw material size) x (Unit Width Unit
of Move / Width of raw material size) x (Height of Unit of Transfer Unit / Height of raw material size)
Then the calculation results are rounded down. The formula in excel is as follows: = ROUNDDOWN
(Length of Unit of Transfer Unit / Length of raw material size; 0) * ROUNDDOWN (Unit Width of Unit
Move / Width of raw material size; 0) * ROUNDDOWN (Height of Unit of Transfer Unit / Height of raw
material size; 0 )
The number of transfer units for GBB and GBJ are obtained with the following calculations:
Number of transfer units = maximum capacity / Unit of Transfer Unit
Then the calculation results are rounded up.
* Pallet Space Needs
Amount determined by the transfer.
The number of basic transfer units for GBB and GBJ are obtained with the following calculations:
Base number of transfer unit = Number of transfer units
The calculation results are rounded up.
Area / Base Unit is obtained by calculation as follows:
Area / Base Unit = Length of unit size of displacement x Width of size of transfer unit
Basic Area
Base Area = Number of basic units of transfer x Unit area
V olume
Volume = Base area x Height of the transfer unit x Total amount * Total base area = Total base area of ​all
raw materials
* Allowances (20%) = Total Base Area x 20%
* Total = Total Base Area + Benefits

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Next is the calculation of the material acceptance area and delivery of raw materials.

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3. Supporting calculation area
At this stage calculations are made on the area of the office and the extent of other supporting facilities.
a. Area of Office
Procedure for making office areas:
● Make a list of Human Resources (HR) needs
● Make details of equipment contained in office space.
● Calculate the Area of an Office based on the equipment used
● Calculating Area for supporting facilities
● Make a recapitulation of the calculation of the entire area

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4. Area Allocation Diagrams (AAD) Conditions for Making:
1. Made with a size of 1: 500 of actual size. Pay attention to the engine size and special needs of
each room and adjust the specifications on the calculation of floor area.
2. AAD made is AAD production and warehouse for product and process layout.
3. AAD that is made not only describes the location and extent of space needed, but must have the
flow of goods from the warehouse of raw materials to the warehouse of finished goods.
4. AAD is made with regard to its beauty. So, to differentiate a location from another location, a line
thickness setting is used
varies and shading.

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Chapter 3: Data Processing

1.1. Area of the machine calculation

First, we need to calculate the quantity needed for each machine. In Product
Layout we used the data given in Route Sheet while in Process Layout we summarized
the total quantity of machine needed in every process based on module 1.

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 ​ Table 3.1.1 Process Layout Machine Quantity

We then summarized the machine area, work desk area, operator room area,
before and after process material area of every WS both in Process and Product Layout to
obtain the total area of factory.

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​ Table 3.1.2 Process Layout Machine Calculation

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 ​ Table 3.1.3 Product Layout Machine Calculation

1.2. Area of the factory calculation

In order to gain Area of the factory calculation, we multiplied each WS area with
machines needed in every WS.

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Table 3.2.1 Process Layout Factory Calculation

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 Table 3.2.2 Product Layout Factory Calculation

1.3. Warehouse Area Calculation

2 Types of WS for each Product and Process Layout were needed to calculated,
GBB and GBJ. In GBB, the total area was obtained by summarized the area of every

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material that has passed several calculation considering different quantity needed for each
of them.

GBB

Table 3.3.1 GBB Area Calculation

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GBJ

Table 3.3.2 GBJ Area Calculation

The area of GBJ and GBB then summarized with several other areas to obtain
Total Warehouse Area for each Product and Process Layout.

Product Layout

​Table 3.3.3 Total Warehouse Area for Product Layout

Process Layout

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 Table 3.3.4 Total Warehouse Area for Process Layout

1.4. Office and supporting area calculation

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1.5. Area Allocation Diagram (AAD)

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2. Chapter 4: Analysis
Area of the Machine Calculation
In this section, we calculate the size of each facility without considering the quantity of machine
needed.
5 Types of machines were used during the whole manufacturing process, Mesin
Pemotong Kayu, Mesin Gerinda Porter-Cable PC60TAG, Mesin Bor Black+Decker LDX120C,
Kuas Wooster Q3108, Palu Maxcraft 6026, Kunci Pas Stanley 90-947, and Gunting Westcott
whereas dimension for each machine were provided.
There are 2 calculation we’ve done, for the Product Layout and Process Layout.
485 and 507 machine needed in total for Product and Process Layout consecutively. The process
of manufacturing Folding Ladder Step were divided into 5 WS in Process Layout, equal to 5
production line, which are SK.Pemotongan Kayu, SK. Pengamplasan Kayu, SK. Pengeboran
Kayu, SK. Pernis dan Pengecatan Kayu and SK. Perakitan dan Pengemasan. SK. Pemotongan
Kayu is the biggest WS due to every component needs to be cut before moving to another WS,
and followed by SK. Pengamplasan, SK. Perakitan, SK. Pengeboran and SK. Pernis respectively.
On the other hand, in Product Layout each component have 1 production line with the
sub-assembly and assembly process all merged into 1 line. As a result of its role as facility with
most operations (5 operations) The Back Leg (Component 1) Facility is the largest among others,
occupied almost 27 m2. It is almost twice the size of Top Support (Component 9) Facility, as the
smallest facility with fewest operations (2 operation).

Area of Factory Calculation

In this section, the area we gathered from previous calculation were multiplied by the quantity of
machine needed.
In Process Layout, SK. Pemotongan as the largest facility from previous calculation, is
also facility which needed the most machines (222 cutting machines). Consequently, it remained
as the largest facility with 2143 m2 or almost 4 times larger than SK. Pernis dan Pengecatan Kayu
as the smallest (55.728 m2). Total area needed to apply Process Layout is 3068.976 m2.
Not much different, in Product Layout Back Leg (Component 1) facility, thanks to its 5
process; Pemotongan, Pengamplasan, Pengeboran, another Pemotongan, and another Pengeboran

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remains as the largest facility with 708.78 m2. Total area needed to apply Product Layout is
4098.742 m2.

Area of Warehouse Calculation

There are 2 warehouses in the manufacturing plant, raw material warehouse (GBB) and finished
goods warehouse (GBJ). Several factors to be considered in this calculation were types and
dimensions of material, quantity received, vehicle needed to transport, and the needs of Pallet
Room.
In GBB, almost half of the area (27.91 m2 out of 52.945 m2 before allowance) were used
to store 8 types of Kayu Jati Belanda, all comes in different dimension, while the rest were split
by small sizes raw materials such as ​Cincin Penutup Melebar, Cincin Penutup Pengunci, Mur
Segi Enam, Cat Kayu, Pernis, ​etc. All of the woods which we can categorized as large goods
were all sent by truck while other goods were transported by pick up car.
The company was given target to produce 200pcs of Folding Ladder Step with dimension
of 0.375m x 0.635m x 0.12m each day and is to be transported by truck. To store all finished
goods, DN Consulting needs to have GBJ with size of 85.5 m2 in total. The area needed for GBB
and GBJ are 200.45 m2 and 222.42 m2. On top of that, area needed for GBJ and GBB in both
product and process layout are both the same due to same amount of goods received as raw
materials and both are targeted to produce same quantity of ladder.

Office and Supporting Area Calculation

In this section we are calculating human resource, and the factory area. In human resource
calculation, this company needed total of 188 workers divided into 5 departments. Chief,
Technical, Production, Warehouse, and General Departments. The company also given a
workspace for every section of department which needed total 339m2 of working area, supporting
area need to provides 3804m2 for 14 section of supporting area consist pos keamanan, pantry,
klinik, etc.

Area Allocation Diagram (​AAD)

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 This section shows the final formation of the factory layout that was built. However, adjustments
may not violate the level of the relationship that has been established. That is, the center of
activity which must be far apart is not justified to be close together or vice versa, which has a
level of close relations not justified far apart. In our company, our designer also gets a general
form of material flow that will apply.
In our company shows that we are using process layout with line manufacturing starting
from “Gudang bahan baku” ends in “Gudang bahan jadi” because this company aiming for
efficiency

3. Chapter 5: Conclusion
Based on the analysis, we knew this company aiming for efficiency to manufacture
Ladder Folding Step by Process Layout we need more machines compared to Product Layout
(507 and 485 respectively) therefore it might taken as considerations regarding cost to buy the
machines. 5 production lines for each WS of Process Layout were needed compared to 9 lines for
each component of the ladder for Product Layout. Consequently, Product Layout occupies more
space than Process Layout regarding area of factory calculation (4098.742 m2 compared to
3068.976 m2)

4. References
· Modul Praktikum Tata Letak Pabrik
· Mubarak, Andri. S.T, M.Sc​Introduction to Plan Layout Design

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