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Layout Planning Models

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Presentasi berjudul: "Layout Planning Models"— Transcript presentasi:

1 Layout Planning Models
Chapter VIII Layout Planning Models BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

2 PERANCANGAN TATA LETAK FASILITAS
Layout till This Point Coordinating facilities planning with other organizational units Facility requirements a product design, process design, schedule design Activity relationships and space requirements Personnel requirements BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

3 PERANCANGAN TATA LETAK FASILITAS
Basic Layout Types Fixed product layouts the workstations are brought to the material Product layouts based on the processing sequence Group layout; Product family layout high degree of intradepartmental flow Process layout high degree of interdepartmental flow BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

4 PERANCANGAN TATA LETAK FASILITAS
Basic Layout Types BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

5 PERANCANGAN TATA LETAK FASILITAS
Basic Layout Types Product Layout Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow Linear arrangement of workstations to produce a specific product Process Layout Layout that can handle varied processing requirements Centers/machines grouped by process they perform Fixed Position Layout Layout in which the product or project remains stationary; workers, materials, and equipment are moved as needed Used in projects where the product cannot be moved BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

6 PERANCANGAN TATA LETAK FASILITAS
Hybrid Layouts Cellular layouts group machines into machining cells Flexible manufacturing systems automated machining & material handling systems Mixed-model assembly lines produce variety of models on one line BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

7 PERANCANGAN TATA LETAK FASILITAS
Layout Formats Group Technology Layout Just-in-Time Layouts Assembly-lines or Group Technology formats Fixed Position Layout e.g. Shipbuilding BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

8 Manufacturing Process Layout
Milling Department Lathe Department Drilling Department L L M M D D D D M M D D D D L L L L G G G P G G G P L L Grinding Department Painting Department L L A A A Receiving and Shipping Assembly BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

9 Service Process Layout
Women’s Lingerie Shoes House- wares Dresses Cosmetics & Jewelry Children’s Department Sportswear Entry & Seasonal Men’s BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

10 PERANCANGAN TATA LETAK FASILITAS
Product Layout IN OUT BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

11 A U-Shaped Production Line
1 2 3 4 5 6 7 8 9 10 IN OUT Workers BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

12 PERANCANGAN TATA LETAK FASILITAS
Cellular Layout Cellular Manufacturing Layout in which machines are grouped into a cell that can process items that have similar processing requirements Group Technology The grouping into part families of items with similar design or manufacturing characteristics BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

13 PERANCANGAN TATA LETAK FASILITAS
Group Technology One Worker, Multiple Machines Machine 2 Machine 3 Machine 1 Materials in Finished goods out Machine 4 Machine 5 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

14 PERANCANGAN TATA LETAK FASILITAS
Group Technology Parts Families BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

15 Receiving and shipping
Group Technology Lathing Milling Drilling D D L L M M D D L L M M Grinding L L M M G G Assembly L L G G A A Receiving and shipping A A G G BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

16 Receiving and shipping
Group Technology Lathing Milling Drilling D D L L M M D D L L M M Grinding L L M M G G Assembly L L G G A A Receiving and shipping A A G G (a) Jumbled flows in a job shop without GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

17 Receiving and shipping
Group Technology Lathing Milling Drilling D D L L M M D D L L M M Grinding L L M M G G Assembly L L G G A A Receiving and shipping A A G G (a) Jumbled flows in a job shop without GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

18 Receiving and shipping
Group Technology Drilling D Grinding G Milling M Assembly A Lathing Receiving and shipping L (a) Jumbled flows in a job shop without GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

19 PERANCANGAN TATA LETAK FASILITAS
Group Technology Cell 3 L M G Cell 1 Cell 2 Assembly area A D Shipping Receiving (b) Line flows in a job shop with three GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

20 PERANCANGAN TATA LETAK FASILITAS
Group Technology Cell 3 L M G Cell 1 Cell 2 Assembly area A D Shipping Receiving (b) Line flows in a job shop with three GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

21 PERANCANGAN TATA LETAK FASILITAS
Group Technology Cell 3 L M G Cell 1 Cell 2 Assembly area A D Shipping Receiving (b) Line flows in a job shop with three GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

22 PERANCANGAN TATA LETAK FASILITAS
Group Technology Cell 3 L M G Cell 1 Cell 2 Assembly area A D Shipping Receiving (b) Line flows in a job shop with three GT cells BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

23 PERANCANGAN TATA LETAK FASILITAS
Layout Procedures Construction type develop a new layout “from scratch” Improvement type generate layout alternatives based on an existing layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

24 Apple’s Plant Layout Procedure
Procure the basic data Analyze the basic data Design the procedure process Plan the material flow pattern Consider the general material handling plan Calculate equipment requirements Plan individual workstations Select specific material handling equipment Coordinate groups of related operations Design activity interrelationships BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

25 Apple’s Plant Layout Procedure
Determine storage requirements Plan service and auxiliary activities Determine space requirements Allocate activities to total space Consider building types Construct master layout Evaluate, adjust, and check the layout with the appropriate persons Obtain approvals Install the layout Follow up on implementation of the layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

26 Reed’s Plant Layout Procedure
Analyze the product or products to be produced Determine the process required to manufacture the product Prepare layout planning charts Determine workstations Analyze storage area requirements Establish minimum aisle widths Establish office requirements Consider personnel facilities and services Survey plant services Provide for future expansion BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

27 PERANCANGAN TATA LETAK FASILITAS
Layout Planning Chart Flow process, including operations, transportation, storage, and inspections Standard times for each operation Machine selection and balance Manpower selection and balance Material handling requirements BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

28 PERANCANGAN TATA LETAK FASILITAS
Muther’s Systematic Layout Planning (SLP) Procedure BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

29 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

30 PERANCANGAN TATA LETAK FASILITAS
Relationship Diagram BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

31 Space Relationship Diagram
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

32 Alternative Block Layout
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

33 Algorithmic Approaches
The relative placement of departments on the basis of their “closeness ratings” or “material flow intensities” is one that can be reduced to an algorithmic process. Algorithm classification Type of input data qualitative “flow” data (relationship chart) quantitative flow matrix (from-to chart); numerical values of closing rating ~ mostly used both qualitative and quantitative (BLOCPLAN, used one at a time) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

34 Algorithm Classification
Objective function “distance-based”: Minimizing the sum of flows times distances (from-to chart) – QAP: “adjacency-based”: maximizing an adjacency score (relationship chart) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

35 Algorithm Classification
Normalized adjacency score (efficiency rating) Normalized adjacency score for an X relationship BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

36 Algorithm Classification
Layout representation discrete (grid size<->computational burden) continuous (rectangular building and department shapes) department cannot be split Any grid assigned to a department must be “reachable” form any other such grid enclosed void (atrium) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

37 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

38 Algorithm Classification
Layout improvement start with an initial layout improve through incremental changes Layout construction develop a layout from scratch given dimension (basic assumption in the book) “green field”: site plan BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

39 Relationship Diagramming for New Layouts
Step 1. Select the first department to enter the layout - select the department with the greatest # of “A” Step 2. Select the second department to enter the layout – have an “A” with the 1st department Step 3. Select the third department to enter the layout - AA, AE, AI, A*, EE, EI, E*, II, I* Step 4. Determine the fourth department to enter the layout - AAA, AAE, AAI, AA*, AEE, AEI Step n. Department n is placed according to the rules described in Steps 3 and 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

40 Pairwise Exchange Method for Layout Improvement
Minimize the total cost of transporting materials among all departments in a facility Rectilinear distance, from centroid to centroid BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

41 PERANCANGAN TATA LETAK FASILITAS
Example Four departments with equal size Material flow matrix Distance matrix BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

42 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

43 Pairwise Exchange Method
Remark does not guarantee to yield the optimal solution: local optimality may cycle back to one alternative symmetric layout may occur can be accomplished only if the department pair considered are of equal size or if they share a common border BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

44 Graph Based Construction Methods ( GBCM )
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

45 Perancangan Tata Letak Dengan Metode Grafik
Merupakan metode perancangan layout dengan menggunakan adjacency graph (grafik kedekatan)untuk memperoleh bobot terbesar Berdasarkan from-to-chart (keterkaitan aktivitas) Node :menyatakan departemen/aktivitas Arc : menghubungkan departemen Angka : menyatakan tingkat kedekatan (closeness) Bobot terbesar = jumlah nilai busur-busur BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

46 PERANCANGAN TATA LETAK FASILITAS
Contoh metode grafik Dep 1 2 3 4 5 60 100 50 40 65 30 80 10 Diketahui From-to-chart BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

47 Alternatif block layout
4 3 5 2 1 80 60 65 40 100 Alternatif block layout 3 4 2 5 1 80 65 10 50 60 (b) (a) BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

48 PERANCANGAN TATA LETAK FASILITAS
Bobot layout (a) Bobot layout (b) Busur Bobot 1 - 2 1 - 4 1 - 5 2 - 4 3 - 4 3 - 5 4 - 5 60 50 65 80 10 1 - 3 2 - 3 100 40 265 terpilih 345 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

49 Grafik kedekatan terakhir
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

50 Langkah-langkah metode grafik
Pilih pasangan departemen yang mempunyai bobot terbesar, dari contoh (block layout b) terpilih dept 1 dan 3. Hubungkan node 1 dan 3 1 3 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

51 PERANCANGAN TATA LETAK FASILITAS
Langkah 2 Pilih departemen ke 3 yang akan masuk dalam grafik , dengan menjumlah bobot departemen yang belum terpilih dengan departemen a dan 3 Pilih pasangan yang mempunyai nilai terbesar BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

52 PERANCANGAN TATA LETAK FASILITAS
1 - 3 2 4 5 60+40=100 50+80 =130 0 + 0 = 0 - Terpilih 1 3 4 50 100 80 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

53 PERANCANGAN TATA LETAK FASILITAS
Langkah 3 Memilih departemen yang belum terpilih dalam grafik Jumlahkan bobot departemen yang belum terpilih dengan dept 1,3 dan 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

54 PERANCANGAN TATA LETAK FASILITAS
1 – 3 - 4 2 5 =160 = 10 Terpilih - 1 3 4 50 100 80 2 65 40 60 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

55 PERANCANGAN TATA LETAK FASILITAS
Langkah 4 Karena tinggal departemen 5 yang belum masuk grafik, maka ditentukan bidang yang akan menjadi tempat departemen 5 Bidang segitiga yang terbentuk: 1 – 2 – 3 1 – 2 – 4 1 – 3 – 4 2 – 3 – 4 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

56 PERANCANGAN TATA LETAK FASILITAS
1-2-3 1-2-4 1-3-4 2-3-4 5 0+30+0=30 = 40 terpilih 0+0+10= 10 = 40 1 3 4 50 100 80 2 65 40 60 5 10 30 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

57 PERANCANGAN TATA LETAK FASILITAS
Bobot layout (b) Busur Bobot 1 - 2 1 – 3 1 – 4 1 - 5 2 - 3 2 - 4 2 - 5 3 – 4 4 - 5 60 100 50 40 65 30 80 10 435 Langkah 5 Menyusun ulang block layout berdasarkan grafik kedekatan BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

58 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

59 PERANCANGAN TATA LETAK FASILITAS
Contoh BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

60 PERANCANGAN TATA LETAK FASILITAS
penyelesaian Bobot terbesar adalah dept A dan B A B BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

61 PERANCANGAN TATA LETAK FASILITAS
Perhitungan bobot dept A dan B dengan dept yang lain BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

62 PERANCANGAN TATA LETAK FASILITAS
B BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

63 PERANCANGAN TATA LETAK FASILITAS
A – B - C D E F G 10+0+1=11 6+6+0 =12 6+0+2 = 8 0+9+7 = 16 - Terpilih BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

64 PERANCANGAN TATA LETAK FASILITAS
B C 7 9 4 G 6 1 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

65 PERANCANGAN TATA LETAK FASILITAS
A-B-C A-B-G A-C-G B-C-G D E F 10+0+1=11 6+6+0=12 6+0+2=8 10+0+6= 16 6+0+0=6 10+1+6=17 6+2+0=8 0+1+6= 7 0+2+0=2 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

66 PERANCANGAN TATA LETAK FASILITAS
B C 8 13 5 G 7 9 D 1 10 6 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

67 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

68 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

69 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

70 Computer-Aided Layout Techniques
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

71 Evaluation and Interchange in CRAFT
Interchanges are only possible if Depts. are the same size; or Adjacent (a necessary but not sufficient condition) Estimate the potential saving for an interchange For evaluation only the centroids are swapped (error?) Select the best among all possible interchanges Actually perform the interchange Path-dependent heuristic (locally optimal) Try different initial solutions or exchange options the error in estimated cost may go either direction BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

72 PERANCANGAN TATA LETAK FASILITAS
Dummy Departments May be used to Fill building irregularities Represent obstacles or unusable areas in the facility (fixed location) Represent extra space in the facility Aid in evaluating aisle locations in the final layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

73 PERANCANGAN TATA LETAK FASILITAS
Example 6.1 BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

74 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

75 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

76 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

77 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

78 PERANCANGAN TATA LETAK FASILITAS
BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

79 PERANCANGAN TATA LETAK FASILITAS
The Impact of Change Plant layout situations Changes in the design of existing product, the introduction of new products Changes in the processing sequence for existing products Changes in production quantities and schedules - the need for capacity changes Changes in production strategies BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

80 PERANCANGAN TATA LETAK FASILITAS
Flexibility Can be achieved by utilizing modular office equipment, workstations, and material handling equipment installing general purpose production equipment utilizing a grid-based utility and services system using modular construction BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS

81 PERANCANGAN TATA LETAK FASILITAS
Flexible Layout BAMBANG RISDIANTO PERANCANGAN TATA LETAK FASILITAS


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