ABSTRAK

Henry Hutomo Alim:

Skripsi
Perancangan ulang tata letak fasilitas PT. Steel Pipe Industry of Indonesia
Unit 1 Gudang 3

PT. Steel Pipe Industry of Indonesia adalah perusahaan yang bergerak di

bidang manufaktur pipa baja. Alur proses produksi yang kurang baik di Unit 1
Gudang 3 mengakibatkan perusahaan mengeluarkan cost yang berlebih untuk
kegiatan transportasi aliran barangnya. Hal ini tentunya juga akan mengakibatkan
semakin kecilnya output yang dihasilkan oleh perusahaan khususnya di gudang 3.
Tugas akhir ini, melakukan perancangan tata letak fasilitas dengan
menggunakan algoritma improvement untuk mencari alternatif tata letak fasilitas
yang menghasilkan momen terkecil. Simulasi juga diperlukan untuk menghitung
output yang dihasilkan dari tiap model simulasi agar didapatkan model yang
terbaik dan menghasilkan output yang lebih besar. Hasil yang didapat dari
penggunaan algoritma improvement yang terbaik yaitu layout dengan
menggunakan algoritma BLOCPLAN dengan total momen sebesar 1153871.08.
Model simulasi yang menghasilkan output terbesar yaitu model penambahan
crane. Total output dengan menggunakan model ini yaitu sebesar 32966 untuk
proses hydrotest 1 dan 136819 untuk proses hydrotest 5 dengan menggunakan
Promodel 10 selama 48 hari.
Kata Kunci:
Tata Letak Fasilitas, BLOCPLAN, Simulasi, Peningkatan Output

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 ABSTRACT

Henry Hutomo Alim:

Thesis
Relayout The Facility Layout of PT. Steel Pipe Industry of Indonesia Unit
1 Werehouse 3

PT. Steel Pipe Industry of Indonesia is a manufacturing company that

focus in steel pipe. The flow of the production process at Unit 1 Werehouse 3 is
not enough good, it will cause that company spent much cost for the transport
activities. It would also decrease the output especially in werehouse 3.
This thesis, doing relayout the facility layout with using improvement
algorithm to search for alternative layouts that produce the smallest moment.
Simulation is also necessary to calculate the output of each simulation model in
order to obtain the best models and generate greater output. The results obtained
from the layouts which using BLOCPLAN algorithm with a total moment of
1153871.08. The simulation model that produces the largest output is the adding
crane model. Total output by using this model is equal to 32966 for the hydrotest
1 and 136819 for the hydrotest 5.
Keyword:
Layout Design, BLOCPLAN, Simulation, output increase

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 DAFTAR ISI

LEMBAR JUDUL ................................................................................................. i

LEMBAR PENGESAHAN .................................................................................. ii

LEMBAR PUBLIKASI ......................................................................................... iii

KATA PENGANTAR .......................................................................................... iv

ABSTRAK .............................................................................................................. v

ABSTRACT .......................................................................................................... vi

DAFTAR ISI ....................................................................................................... vii

DAFTAR TABEL ................................................................................................ ix

DAFTAR GAMBAR ............................................................................................ xi

DAFTAR RUMUS ............................................................................................. xiii

DAFTAR LAMPIRAN ....................................................................................... xiv

1. PENDAHULUAN ........................................................................................... 1
1.1. Latar Belakang .......................................................................................... 1
1.2. Rumusan Masalah ..................................................................................... 2
1.3. Tujuan ....................................................................................................... 2
1.4. Batasan Masalah ....................................................................................... 2
1.5. Sistematika Penulisan ............................................................................... 2

2. DASAR TEORI ............................................................................................... 4

2.1. Perancangan Tata Letak Fasilitas .............................................................. 4
2.2. Pertimbangan Perancangan Ulang Tata Letak Fasilitas ............................ 6
2.3. Activity Relationship Chart ....................................................................... 7
2.4. Metode Perancangan Tata Letak Fasilitas ................................................ 8
2.4.1. Algoritma BLOCPLAN .................................................................. 8
2.4.2. Algoritma CRAFT ........................................................................ 10
2.5. Pengukuran Jarak Antar Fasilitas ............................................................ 11
2.6. Simulasi ................................................................................................... 12

3. METODE PENELITIAN............................................................................... 15
3.1. Metode Penelitian ................................................................................... 15
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4. PENGOLAHAN DAN ANALISIS DATA .................................................. 19
4.1. Gambaran Umum Perusahaan ................................................................. 19
4.1.1. Proses Produksi ............................................................................. 19
4.2. Pengambilan Data ................................................................................... 23
4.3. Tata Letak Fasilitas Perusahaan Kondisi Saat Ini ................................... 23
4.4. Tata Letak Fasilitas Improvement ........................................................... 30
4.4.1. Tata Letak Fasilitas Improvement Algoritma CRAFT ...................31
4.4.2 Tata Letak Fasilitas Improvement Algoritma BLOCPLAN.......... 36
4.5. Simulasi Layout Awal ............................................................................ 41
4.5.1. Waktu Proses..................................................................................42
4.5.2. Material Handling......................................................................... 44
4.5.3. Downtime .......................................................................................46
4.5.4. Replikasi.........................................................................................47
4.5.5. Verifikasi Model ............................................................................47
4.5.6. Validasi Model ...............................................................................48
4.5.7. Simulasi Model Layout Improvement ............................................49
4.6. Simulasi Solusi Awal dengan Perubahan Posisi Crane .......................... 52
4.6.1. Analisa Hasil Solusi Layout Awal Path Network X ......................53
4.6.2. Analisa Hasil Solusi Layout Awal Path Network Y ......................55
4.7. Simulasi Solusi Penambahan Crane ....................................................... 57
4.8. Simulasi Solusi Penambahan Crane dengan Perubahan Posisi Crane ... 60
4.8.1. Analisa Hasil Solusi Penambahan Crane Path Network X............61
4.8.2. Analisa Hasil Solusi Penambahan Crane Path Network Y............63
4.8.3. Analisa Hasil Solusi Penambahan Crane Path Network Z ............65

5. KESIMPULAN .............................................................................................. 69

DAFTAR PUSTAKA ........................................................................................... 70

LAMPIRAN ...........................................................................................................71

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 DAFTAR TABEL

2.1. Kode, Nilai dan Hubungan ARC ...........................................................................8

4.1. Ketentuan Peletakan WIP ...............................................................................25

4.2. Penamaan Kode Fasilitas ................................................................................25

4.3. Jarak Antar Fasilitas Layout Awal ................................................................. 27

4.4. Frekuensi Antar Fasilitas Layout Awal ...........................................................27

4.5. Jarak Antar Fasilitas Layout Perusahaan Kondisi Saat ini dengan Penambahan

Hydrotest 5 ......................................................................................................29

4.6. Frekuensi Antar Fasilitas Layout Perusahaan Kondisi Saat ini dengan

Penambahan Hydrotest 5.................................................................................30

4.7. Dimensi Asli ...................................................................................................31

4.8. Hasil Analisa CRAFT Tipe Pertukaran 2 Departemen dan Total Momen yang

Dihasilkan pada Layout Baru ..........................................................................32

4.9. Jarak Antar Fasilitas Layout Improvement CRAFT Tipe Pertukaran 2

Departemen .....................................................................................................34

4.10 Hasil Analisa CRAFT Tipe Pertukaran 3 Departemen dan Total Momen yang

Dihasilkan pada Layout Usulan .................................................................... 35

4.11. Jarak Antar Fasilitas Layout Improvement CRAFT Tipe Pertukaran 3

Departemen ...................................................................................................36

4.12. Ukuran Luas Area Gudang 3 dan Ukuran Fasilitas-fasilitas Gudang 3 ....... 37

4.13. Activity Relationship Chart tiap Departemen ...............................................38

4.14. Hasil Analisa BLOCPLAN yang Dihasilkan pada Layout Usulan .............. 38

4.15. Jarak Antar Fasilitas Layout Improvement BLOCPLAN..............................40

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4.16. Perbandingan Total Momen dari Seluruh Layout .........................................41

4.17. Jumlah Pipa tiap Batch ..................................................................................44

4.18. Lingkup Area Kerja Alat Material Handling................................................45

4.19. Matriks Waktu Perpindahan Alat Material Handling...................................46

4.20. Waktu Downtime dan Jam Kerja di Mesin Mill 1........................................ 46

4.21. Output Perusahaan tiap Proses ......................................................................48

4.22. Perbandingan Output Simulasi Awal 48 Hari dan Simulasi Layout

Improvement 48 Hari.....................................................................................50

4.23. Pembagian Alur Path Network .....................................................................52

4.24. Perbandingan Output Simulasi Layout Awal Path Network X dan Simulasi

Layout Awal Path Network Y Selama 48 Hari .............................................53

4.25. Perbandingan Output Simulasi Layout Awal dan Simulasi Penambahan

Crane selama 48 Hari ...................................................................................58

4.26. Perbandingan Output Simulasi Layout Penambahan Crane Path Network X,

Path Network Y dan Path Network Z Selama 48 Hari .................................61

4.27. Perbandingan Utilitas Crane dari Simulasi Layout Awal dan Simulasi

Penambahan Crane .......................................................................................68

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 DAFTAR GAMBAR

3.1. Flowchart Metode Penelitian ............................................................................ 15

4.1. Hasil Penataan Layout Awal ......................................................................... 26

4.2. Hasil Penataan Layout Perusahaan Kondisi Saat ini dengan Penambahan

Hydrotest 5 ......................................................................................................28

4.3. Layout Fasilitas Usulan Improvement Setelah Penyesuaian dalam Analisa

CRAFT Tipe Pertukaran 2 Departemen ..........................................................33

4.4. Layout Fasilitas Usulan Improvement Setelah Penyesuaian dalam Analisa

CRAFT Tipe Pertukaran 3 Departemen ..........................................................35

4.5. Layout Fasilitas Usulan Improvement dalam Analisa BLOCPLAN ............. 39

4.6. Hasil output Run-Test Proses Mill 1 Diameter ¾”, Tebal 1,9 mm dan Panjang

6 m...................................................................................................................42

4.7. Grafik Uji Kenormalan Data Proses Mill 1 Diameter ¾”, Tebal 1,9 mm dan

Panjang 6 m (Kolmogorov Smirnov Test) .......................................................43

4.8. Hasil Output Minitab Uji One-Sample T ........................................................48

4.9. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model Awal

dengan Model Layout Improvement............................................................... 50

4.10. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model Awal

dengan Model Layout Improvement ............................................................ 51

4.11. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model Awal

dengan Model Awal Path Network X...........................................................54

4.12. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model Awal

dengan Model Awal Path Network X...........................................................55

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4.13. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model Awal

dengan Model Awal Path Network Y...........................................................56

4.14. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model Awal

dengan Model Awal Path Network Y...........................................................57

4.15. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model Awal

dengan Model Penambahan Crane ...............................................................59

4.16. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model Awal

dengan Model Penambahan Crane ...............................................................59

4.17. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model

Penambahan Crane dengan Model Penambahan Crane Path Network X ...62

4.18. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model

Penambahan Crane dengan Model Penambahan Crane Path Network X ...63

4.19. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model

Penambahan Crane dengan Model Penambahan Crane Path Network Y ...64

4.20. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model

Penambahan Crane dengan Model Penambahan Crane Path Network Y ...65

4.19. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 5 Model

Penambahan Crane dengan Model Penambahan Crane Path Network Z ....66

4.20. Hasil Output Minitab Two Sample T-Test Proses Hydrotest 1 Model

Penambahan Crane dengan Model Penambahan Crane Path Network Z ....67

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 DAFTAR RUMUS

2.1. R-Score............................................................................................................. 9

2.2. Rel-dist Score ................................................................................................... 9

2.3. Lower Bound .................................................................................................... 9

2.4. Upper Bound .................................................................................................... 9

2.5. Total Momen CRAFT .................................................................................... 10

2.6. Perhitungan Jarak dengan Metode Rectilinier ............................................... 12

2.7. Uji Replikasi Kecukupan Data ....................................................................... 14

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 DAFTAR LAMPIRAN

1. Layout Usulan Modifikasi ................................................................................ 71

2. Data Waktu Siklus............................................................................................ 74

3. Uji Independensi .............................................................................................. 85

4. Uji Kenormalan ................................................................................................ 90

5. Uji Distribusi .................................................................................................... 93

6. Downtime ......................................................................................................... 94

7. Presentase Output ..............................................................................................99

8. Perhitungan BEP ...............................................................................................105

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