elisa_kusrini@yahoo.com
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1. Prinsip Perancangan dan Layout
Pergudangan
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Perancangan dan Layout Pergudangan
• Sediakan
transportation
interface.
• Sediakan ruang order-
picking.
• Sediakan ruang
penyimpanan.
• Sediakan ruang Kantor,
dan serbaguna.
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Tujuan Perancangan dan Layout
Pergudangan
– Penggunaan
kapasitas volume
– Perlindungan
– Efisiensi
– Mekanisasi
– Produktifitas
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Perancangan dan Layout Pergudangan
Faktor Komoditi :
Kepopuleran
Similarity
Ukuran
Karakteristik
Utilisasi luas lantai
Prinsip Dasar Lokasi Penyimpanan
Kepopuleran (popularity)
prinsip meletakkan item yang memiliki aksesibilitas
terbesar di titik I/O (titik input-output) tertentu.
Popularity menggunakan suatu rasio R/S atau S/R dengan
S adalah Shipping dan R adalah Receiving. Apabila rasio
R/S suatu item terbesar, maka item didekatkan dengan
titik I/O dan sebaliknya
Kepopuleran (popularity)
Similarity :
Storage conditions
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Ukuran
Komponen-komponen kecil yang disimpan dalam gudang yang dirancang
khusus untuk komponen-komponen besar akan sangat membuang-buang
luas lantai gudang. Namun pada saat komponen-komponen besar akan
disimpan di dalam gudang, komponen tidak akan muat. Oleh karena itu
perlu diterapkan beberapa ukuran lokasi penyimpanan
Karakteristik
i) Material mudah rusak, sehingga lingkungan tempat
penyimpanan harus ideal.
ii) Bentuknya unik, sehingga menimbulkan masalah dalam
area penyimpanan dan pemindahan barang.
iii) Item mudah hancur, sehingga harus diperhatikan
tingkat kelembaban, ukuran unit load dan metode
penyimpanan.
iv) Material berbahaya, sehingga harus menyimpannya
pada lokasi tersendiri.
v) Keamanan material berkaitan dengan proses
pemindahan bahan dimana diusahakan agar barang
tidak mengalami benturan.
vi) Compability merupakan karakteristik penyimpanan
item kimiawi yang mudah berekasi dengan zat kimia
lainnya.
Utilisasi Kapasitas Volume Gudang
Cube Utilization
Product Product
C A
• Lokasi Tetap
– Stock Keeping Unit (SKU) ditempatkan
pada suatu lokasi permanen tertentu dan
tak ada item lain ditempat tersebut
– Sistem lokasi tetap biasanya memiliki
utilisasi kubik yang jelek
Penempatan Stok
• Lokasi Mengambang/Random
– Barang disimpan dimanapun selama ada ruangan
yang cukup
– Keuntungannya adalah meningkatkan utilisasi
kubik
– Model ini menghendaki informasi yang akurat
dan up-to-date
– Biasanya dibutuhkan sistem terkom-puterisasi
Penempatan Stok
• Dua sistem lain yang kadang-kadang digunakan:
– Penyimpanan Point-of-use
• Inventory disimpan dekat dengan dimana
barang dibutuhkan
• Digunakan dalam manufacturing berulang &
Sistem JIT
– Penyimpanan Terpusat
• Semua inventory diletakkan dalam satu
lokasi terpusat
Penempatan Stok
• Keuntungan Penyimpanan Point-of-use
– Material siap diakses untuk pengguna
– Material handling dikurangi atau dihilangkan
– Mengurangi biaya Penyimpanan pusat Central
– Material diakses kapanpun
Penempatan Stok
1. Popularitas
a. 85% of the turnover adalah hasil dari 15% dari materials yang
disimpan.
b. Materials seharusnya disimpan sedemikian hingga jarak perjalanan
adalah berhubungan terbalik dengan dengan popularitas material.
S lo w
M o v in g
M e d iu m F ast E n t ra n c e
M o v in g M o v in g a n d E x it
JENIS LAYOUT GUDANG
Arus garis lurus sederhana
Lokasi barang yang akan disimpan dibedakan antara barang yang bersifat fast
moving dan slow moving. Barang yang bersifat fast moving di simpan didekat
pintu keluar, sebaiknya barang yang bersifat slow moving disimpan dilokasi yang
dekat pintu masuk.
Transshipment
bay
Dock Storage locations Dock
levellers levellers
ADMIN.
UNPACKING &
INSPECTION
DISPATCH
FLOW
ITC M11:U5:5.4-1
LAYOUT PENYIMPANAN GUDANG (6)
Arus U
Layout berbentuk U€Proses keluar masuknya barang melalui lorong
atau gang yang berkelok-kelok € proses penyimpanan dan pengambilan
barang relatif lebih lama.
Dock levellers
Transhipment
bay UNPACKING & DISPATCH
INSPECTION
Storage locations
Administration
FLO W
ITC M11:U5:5.4-2
LAYOUT PENYIMPANAN GUDANG (7)
Arus L
Layout berbentuk L € Proses keluar masuk barang melalui
lorong atau gang €sehingga proses penyimpanan danpengambilan barang
relatif cepat.
4. Penentuan dan Ukuran Selasar (Aisle)
a. Aisle Utama
Lebar aisle = Panjang Alat Material Handling + panjang palet +
operational clearance
(Guidance for Warehousing for Health Commodities, 2005).
b. Aisle Inspeksi
aisle untuk kepentingan inspeksi dengan lebar minimum 0,5 m dan
lebar aisel blok dengan tembok minimum selebar 0,5 m (UKWLA,
2008)
ITC M11:U5:5.5-3
5. MATERIAL
HANDLING
Media Tipe Barang Alat Material Handling
Lantai Oddly shaped, besar dan Crane, Pallet Jack, Forklift,
berat AGV
Box Karet, ukuran agak kecil Crane, Pallet Jack, Forklift,
Hand truck, AGV
Rak Kecil, berat Pallet Jack
Automated gueded vehicle
handtruck
Pallet forklift
crane
Jack
Forklift
truck
Hand trolley
Pallet
truck
ITC M11:U5:5.5-2
Trolley
Semi-automated handling equipment:
conveyor systems
ITC M11:U5:5.5-11
Unloading, putting away and picking
equipment
Picker-stacker truck
Forklift trucks
Maximum
height
15m.
Pantograph
Reach truck
ITC M11:U5:5.5-12
Highly-automated fixed handling
equipment
Maximum
height: 40 m.
Picker-
stacker
crane
Automatically
guided vehicle
ITC M11:U5:5.5-14
Racking Design
Block Stack/ floor pallet stacking , Unit loads are stacked
on top of each other, and stored on the floor in storage lanes
or block, two to ten deep.
Mezzanine
Allow you to change empty overhead space into usable storage
areas, depend on the size of your facility, a mezzanine can be
one two or more level high
Mezzanine
Single Deep Rack
Also known as selective rack, is by far the most common
type of rack used in warehouses today. Loads are stored
only one pallet deep
Double Deep Rack
Similar to selective racking; but pallets are now stored
two rows deep instead of one
Drive in / Drive Thru Rack
Ideal for high pallet quantities of same stock in each
lane.
Space efficiency and high volume storage of block
stacking, with easy access to pallets
Push Back Rack
Provide high density storage capability
similar to double deep rack without need
for a straddle or reach truck. Used in LIFO
inventory rotation system
Push Back Rack
Racking Design Comparison
Block Stack, Unit Mezzanine/ Shelving, Single Deep Rack, Double Deep Rack is Drive in / Drive Thru Push Back Rack pro-
loads are stacked on allow you to change also known as selec- used as a method of in- Rack is generally used vide high density sto-
top of each other, and empty overhead space tive rack, is by far the creasing pallet capacity in when there is large rage capability similar to
stored on the floor in into usable storage most common type of a storage area when the quantity of pallet of the double deep rack
Rack Type storage lanes or block, areas, depend on the rack used in ware- product stored in each same size to be stored without need for a
two to ten deep. size of your facility, a houses today. Loads row is the same. that cannot be self straddle or reach truck.
mezzanine can be one are stored only one stacked more than two Used in LIFO inventory
two or more level high pallet deep high. rotation system
Storage 60% Storage 40% Storage 40% Storage 50% Storage 60 % Storage 60%
Floor Space Utilization
Aisle 40% Aisle 60% Aisle 60% Aisle 50% Aisle 40% Aisle 40%
Typical Occupancy 85-95% 70-80% 70-80% 80-90% 50 – 60% 85-95%
Fair – as conventional High – specifically for High – More than one High – More than one truck Low – High speed High – With bulk (full
gas or diesel powered pieces pick truck can serve rack at can serve rack at one time operation, may cause pallet) movement of pallet
Speed of Throughput trucks are used in this one time damaged goods
kind of operation
suitable only for a very Every bin or shelve can Every pallet can hold Restricted each lane to one Restricted each column Restricted each lane to
limited number of diffe- hold different goods different goods if product lane to one product one product
Stock Variability rent items, product needed
quantities are large
• Damage stock from • Cannot accessed by • Requires the most • Requires the most square • Last in first out • Last in First out
movement & crushing forklift for particular square footage per footage per pallet stored • Typical honeycombing • Required similar weight
• Has inherent dangers level pallet stored lost up to 40% in pallet
Disadvantage such as toppling due to • Every level has to be • Required similar SKU in
45 load instability same SKU each lane
Sarana dan Perlengkapan Gudang
Rak
Compactor
shelving
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ITC M11:U5:5.5-8
Mezzanine Storage
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ITC M11:U5:5.5-9
Steel or plastic
storage bins
Carousel
storage unit
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ITC M11:U5:5.5-10
Post pallets
Shelving
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ITC M11:U5:5.5-7
6. KESELAMATAN DAN KEMANAN
GUDANG
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Keselamatan Gudang
Mencakup tindakan pencegahan dan pengawasan
terhadap:
1) Pergerakan kendaraan
2) Peralatan penanganan material
3) Tata laksana kerja gudang
Pergerakan kendaraan
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KPI Receiving
• Cost – Cost of Receiving per receiving line;
• Productivity – Volume received per man-hour;
• Utilization – Receiving Dock door utilization %;
• Quality – Accurate receipts %;
• Cycle Time – Time taken to process a receipt.
KPI Put Away
• Cost – Cost per put-away line;
• Productivity – Put-away per man-hour;
• Utilization – Utilization % of labour and
equipment;
• Quality – Perfect put-away %;
• Cycle Time – Time taken for each put-away.
KPI Storage
• Cost – Storage cost per item;
• Productivity – Inventory per sq. foot;
• Utilization – % Location and cube occupied;
• Quality – % Location without inventory
discrepancies;
• Cycle Time – Inventory days on hand.
KPI Picking & Packing
• Cost – Cost of picking per order line;
• Productivity – Order lines picked per hour;
• Utilization – Picking labour and equipment
utilization %;
• Quality – Perfect picking lines %;
• Cycle Time – Order Pick cycle time per order.
KPI Shiping
• Cost – Cost of shipping per order;
• Productivity – Order process for shipping per
man hour;
• Utilization – Utilization of shipping docks in %;
• Quality – Perfect shipping %;
• Cycle Time – Shipping time (from the time
order picked to physically movement of the
truck) per order
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