Bab 9-10

Tata Letak
Fasilitas
 Penjadwalan
 Menentukan kapan tenaga kerja,
peralatan, fasilitas yang diperlukan
untuk menghasilkan suatu produk atau
memberikan layanan
 Tahap terakhir dari perencanaan
sebelum produksi terjadi
 Tujuan Fasilitas Tata Letak

Meminimalkan biaya penanganan material

Memanfaatkan ruang secara efisien

Memanfaatkan tenaga kerja secara efisien

menghilangkan hambatan

Memfasilitasi komunikasi dan interaksi antara pekerja , antara pekerja
dan supervisor mereka , atau antara pekerja dan pelanggan

Reduce manufacturing cycle time or customer service time
 Tujuan Fasilitas Tata Letak
 Menghilangkan limbah yang berlebihan
 Memfasilitasi masuk, keluar , dan penempatan material, produk , atau orang-
orang
 menggambungkan ukuran keselamatan dan keamanan

Mempromosikan produk dan layanan berkualita

Mendorong kegiatan perawatan yang tepat

Memberikan kontrol visual operasi atau kegiatan

Memberikan fleksibilitas untuk beradaptasi dengan perubahan kondisi
Meningkatkan kapasitas
 Jenis dasar Layouts

Process Layout
 Mesin dikelompokkan berdasarkan proses yang mereka
lakukan

Product Layout
 Susunan linear dari workstation untuk menghasilkan produk
tertentu
 Fixed Position Layout
 Digunakan dalam proyek di mana produk tersebut tidak dapat
dipindahkan
 Process Layout pada Jasa

Women’s
Shoes Housewares
lingerie

Women’s Cosmetics Children’s

dresses and jewelry department

Women’s Entry and Men’s

sportswear display area department

Figure 5.1
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly

Figure 5.2
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly

Figure 5.2
Manufacturing Process Layout
Milling
Lathe Department Department Drilling Department
M M D D D D
L L

M M D D D D
L L

G G G P
L L

G G G P
L L
Grinding Painting Department
Department
L L
Receiving and A A A
Shipping Assembly

Figure 5.2
 A Product Layout

In

Out

Figure 5.3
 Comparison Of Product
And Process Layouts
PRODUCT LAYOUT PROCESS LAYOUT
1. Description Sequential arrangement Functional grouping
of machines of machines
2. Type of Process Continuous, mass Intermittent, job shop
production, mainly batch production,
assembly mainly fabrication
3. Product Standardized Varied,
made to stock made to order
4. Demand Stable Fluctuating
5. Volume High Low
6. Equipment Special purpose General purpose
7. Workers Limited skills Varied skills

Table 5.1
 Comparison Of Product
And Process Layouts
PRODUCT LAYOUT PROCESS LAYOUT
8. Inventory Low in-process, High in-process,
high finished goods low finished goods
9. Storage space Small Large
10. Material Fixed path Variable path
handling (conveyor) (forklift)
11. Aisles Narrow Wide
12. Scheduling Part of balancing Dynamic
13. Layout decision Line balancing Machine location
14. Goal Equalize work at Minimize material
each station handling cost
15. Advantage Efficiency Flexibility

Table 5.1
 Fixed-Position Layouts


Tipe proyek

Peralatan , pekerja , bahan , sumber informasi lainnya dibawa ke
situs

Tingginya Tenaga kerja terampil

Sering rendah tetap Biaya

Tipe biaya variabel biasanya tinggi
 Designing Process Layouts

Meminimalkan biaya material handling

Blok Diagram
 Minimize nonadjacent loads Minimalkan beban
nonadjacent
 Gunakan ketika data kuantitatif yang tersedia avalaibel

hubungan Diagram
 Berdasarkan preferensi lokasi antara area

 Gunakan ketika data kuantitatif tidak available

 Process Layout
Example 5.1

Load Summary Chart

FROM/TO DEPARTMENT

Department 1 2 3 4 5

1 — 100 50
2 — 200 50
3 60 — 40 50
4 100 — 60
Composite 5Movements Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
12 100 loads 14 0 loads
45 60 loads 15 0 loads
 Process Layout
Example 5.1

Load Summary Chart

FROM/TO DEPARTMENT
1 2 3
Department 1 2 3 4 5

1 — 100 50
2 — 4200 50 5
3 60 — 40 50
4 100 — 60
Composite 5Movements Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
12 100 loads 14 0 loads
45 60 loads 15 0 loads
 Process Layout
Example 5.1
110
Load Summary Chart

FROM/TO 100
DEPARTMENT 200
1 2 3
Department 1 2 3150 4 5
50
50
1 — 100 50 60
2 — 4200 50 5
3 60 — 40 50
40
4 100
Grid 1 — 60
Composite Movements
5 Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
12 100 loads 14 0 loads
45 60 loads 15 0 loads
 Process Layout
Example 5.1

Load Summary Chart

FROM/TO 100
DEPARTMENT 150
1 2 4
Department 1 2 3 4
200 505 40 60
110
1 — 100 50 50
2 — 200 50 3 5
3 60 — 40 50
4 100
Grid 2 — 60
Composite 5Movements Composite
50 Movements
—
23 200 loads 35 50 loads
24 150 loads 25 50 loads
13 110 loads 34 40 loads
12 100 loads 14 0 loads
45 60 loads 15 0 loads
Computerized Layout Solutions

 CRAFT - block
diagramming
 CORELAP -
relationship
diagramming
 Simulation
 Service Layouts

Usually process layouts due to customers needs

Minimize flow of customers or paperwork

Retailing tries to maximize customer exposure to products

Computer programs consider shelf space, demand, profitability

Layouts must be aesthetically pleasing
Designing Product Layouts

Product layouts or assembly lines

Develop precedence diagram of tasks

Jobs divided into work elements

Assign work elements to workstations

Try to balance the amount work of each
workstation
 Line Balancing

Precedence diagram
 Network showing order of
tasks and restrictions on their
performance
 Cycle time
 Maximum time product
spends at any one
workstation
 Line Balancing

Precedence diagram
Cycle time example
 Network showing order of
tasks and restrictions
productionon time
their available
Cd = desired units of output
performance
 Cycle time
(8 hours x 60 minutes / hour)
Cd = time product
 Maximum
(120 units)
spends at any one
workstation 480
Cd = = 4 minutes
120
 Flow Time vs Cycle Time

Cycle time = max time spent at any station
 Flow time = time to complete all stations
 Flow Time vs Cycle Time

Cycle time = max time spent at any station
 Flow time = time to complete all stations

1 2 3
4 minutes 4 minutes 4 minutes

Flow time = 4 + 4 + 4 = 12 minutes

Cycle time = max (4, 4, 4) = 4 minutes
 Efficiency of Line
Minimum number
Efficiency
of workstations

i i

t i t i

E = nC
i=1
N= i=1
Cd
a

where
ti = completion time for element i
j = number of work elements
n = actual number of workstations
Ca = actual cycle time
Cd = desired cycle time
 Line Balancing Process
1. Draw and label a precedence diagram.
2. Calculate the desired cycle time required for the line.
3. Calculate the theoretical
minimum number of workstations.
4. Group elements into workstations,
recognizing cycle time and
precedence constraints.
5. Calculate the efficiency of the line.
6. Stop if theoretical minimum number of workstations on
an acceptable efficiency level reached. If not, go back to
step 4.
Line Balancing
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

Example 5.2
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
B

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
B
40 hours x 60 minutes / hour 2400
Cd = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4
C 0.4
Example 5.2 0.4
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
B
40 hours x 60 minutes / hour 2400
Cd = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4
C 0.4 3
Example 5.2 0.4 workstations
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D
3 D 0.1 none

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

Cd = 0.4
0.2
B N = 2.5

0.1 A D 0.3

C
Example 5.2 0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

Cd = 0.4
0.2
B N = 2.5

0.1 + 0.2 + 0.3 + 0.4 1.0

E= 0.1 A = D 0.3 = 83.3%
= 0.833
3(0.4) 1.2

C
Example 5.2 0.4