BAB 6KESIMPULAN DAN SARAN EVALUASI RANCANGAN TATA LETAK FASILITAS BARU PLANT 3 PT. KOMATSU REMANUFACTURING ASIA.
BAB 6
KESIMPULAN DAN SARAN
6.1. Kesimpulan
Berdasarkan hasil evaluasi dari rancangan tata
letak fasilitas baru plant 1
plant
3
PT.
Komatsu
yang akan dibangun di
Remanufacturing
Asia
didapatkan
bahwa tidak ada masalah dengan aliran material (flow)
dan
kegiatan
fasilitas
(activity)
baru
keleluasaan
departemen
plant
area
yang
3
pada
rancangan
tersebut.
(space)
mengalami
tata
Namun,
terdapat
letak
dari
beberapa
ketidakcukupan
area
sisi
subdalam
peletakan mesin maupun ketidakleluasaan area kerja bagi
operator.
Sub-departemen
–
sub-departemen
tersebut
adalah:
a. Departemen washing
1. Prewash
2. Deep tank
3. Robowash water
4. Robowash chemical
b. Departemen machining
1. Crankshaft grinding 1
2. Crankshaft grinding 2
3. Lathe machine for axle tube
Rancangan
dinyatakan
terhadap
tata
layak
letak
dengan
fasilitas
melakukan
sub-departemen
–
baru
ini
dapat
perluasan
area
sub-departemen
yang
disebutkan di atas. Perluasan area ini akan berdampak
terhadap
ukuran
beberapa
sekitar
sub-departemen
sub-departemen
yang
yang
mengalami
ada
di
perluasan
tersebut. Hal ini dikarenakan perusahaan sudah tidak
130
dapat
memberikan
perluasan
area
secara
keseluruhan,
sehingga yang dapat dilakukan adalah mengurangi luas
area sub-departemen yang masih berlebih.
Sub-departemen
yang
mengalami
dampak
akibat
perluasan area sub-departemen di atas adalah :
a. WIP crankshaft and camshaft
b. Line boring machine
c. Magnaflux
d. WIP axle tube
e. Metal spray room
6.2. Saran
Saran yang dapat diberikan sebagai bahan masukan
bagi perusahaan antara lain :
a. Sistem penanganan material untuk memindahkan engine
dari overhead crane yang berkapasitas 5 ton dan 10
ton hendaknya dipertimbangkan dengan sebaik-baiknya,
karena
crane
apabila
ini
pemindahan
terhambat,
maka
engine
akan
antar
overhead
menghambat
aliran
produksi secara keseluruhan.
b. Pergantian tata letak fasilitas di sub-departemen
assembly
yang
semula
berupa
workstation
terpusat
menjadi lintasan lini seperti yang dicita-citakan
perusahaan hendaknya dilaksanakan setelah masalahmasalah yang dapat menghambat kelancaran berjalannya
lintasan lini dapat teratasi. Berdasarkan pengamatan
penulis,
masalah-masalah
yang
dapat
menghambat
kelancaran berjalannya lintasan lini tersebut antara
lain :
1. Keterlambatan spare part
Masalah
ini
dapat
diatasi
dengan
memperbaiki
sistem inventory dan production planning control.
131
2. Pekerja yang kurang terampil dalam merakit engine
sehingga menyebabkan terjadinya redo (bongkar dan
pasang kembali)
Masalah
ini
dapat
diatasi
dengan
memberikan
training atau pelatihan kepada pekerja mengenai
proses perakitan engine.
3. Kurang
lengkapnya
alat
yang
digunakan
dalam
proses perakitan
Masalah ini dapat diatasi dengan melengkapi alatalat
yang
pekerjaannya
digunakan
tidak
ketidaktersediaan alat.
132
oleh
pekerja
terhambat
sehingga
karena
DAFTAR PUSTAKA
Apple, J.M, 1990, Tata Letak Pabrik dan Pemindahan
Bahan, Institut Teknologi Bandung, Bandung.
Assauri,S., 1977, Manajemen Produksi, Lembaga Penerbit
Fakultas Ekonomi, Universitas Indonesia, Jakarta.
Daryanto, Y, 2003, Perencanaan Tata Letak Fasilitas
Produksi
Berdasarkan
Group
Technology
dengan
Metode Non Linear and Assignment Allocation
Algorithm (Studi Kasus di PT. Swasti Pandawa
Armada, Magelang), Program Studi Teknik Industri,
Fakultas Teknologi Industri, Universitas Atma Jaya
Yogyakarta, Yogyakarta.
Dasi,
P.M.K.D, 2008, Usulan Perancangan Ulang Tata
Letak Fasilitas (Studi Kasus di CV. Pandanus
Internusa, Yogyakarta), Skripsi, Program Studi
Teknik Industri, Fakultas Teknologi Industri,
Universitas Atma Jaya Yogyakarta, Yogyakarta.
Kurniawan, A.A., 2007, Perancangan Ulang Tata Letak
Fasilitas Produksi (Studi Kasus di PT Prestige
Furniture,
Yogyakarta),
Program
Studi
Teknik
Industri, Fakultas Teknologi Industri, Universitas
Atma Jaya Yogyakarta, Yogyakarta.
Lee,
Q., Arild Amundsen, William Nelson, Herbert
Tuttle., 1996, facilities and Workplace Design,
Engineering and Management Press Institute of
Industrial Engineers Norcross Georgia, USA.
Meyers, Fred E dan Stephens, Matthew P., 2005,
Manufacturing
Facilities
Design
and
Material
Handling, 3rd Ed, Prentice Hall, Inc., New Jersey.
Muther, Richard., 1970, Plant Layout and Design,
Handbook of Modern Manufacturing Management, Mc
Graw Hill.
133
Satria, 2007, Plant Layout / Facilities Layout,
Http://www.bysatria.wordpress.com/2007/03/11/plant
-layout-facilities-layout/-20k-, diakses 25 April
2009.
Tompkins, James A., White, John A., Bozer, Yavus A.,
dan Tanchocho, J.M.A., 2003, Facilities Planning,
3th Ed, John Wiley & Sons, Inc., United States of
America.
Wignjosoebroto, S., 2003, Tata Letak Pabrik dan
Pemindahan Bahan, Edisi Ketiga, PT. Guna Widya,
Jakarta.
Yuniarti, A.T., 2009, Usulan Perancangan Tata Letak
Baru Akibat Perluasan Pabrik (Studi Kasus di PT.
Mega
Andalan
Kalasan,
Yogyakarta),
Skripsi,
Program Studi Teknik Industri, Fakultas Teknologi
Industri,
Universitas
Atma
Jaya
Yogyakarta,
Yogyakarta.
134
LAMPIRAN 1
No.
Departemen
1
2
3
Disassy Line
Customer Inspection
Valve Seat
4
Oil & After Cooler
5
6
7
8
9
Nama sub-departemen
Disassy Line
Customer Inspection
Disassy
Roller
Roller
Measurement
Valve seat remove
Deep Tank
Robowash Water
Oil & After Cooler Disassy
Jumlah sub-Ukuran sub-departemen (m2)
departemen
p
l
L
7
4
4,5
18
1
4
4,5
18
1
4,5
1
4,5
2
1
2
2
3,2
1
3,2
1
3,95
1
3,95
1
1,5
1,5
2,25
1
3,5
2,5
8,75
1
2
2
4
1
5
3
15
Robowash
Pulley & Drives
Pulley & Drives Disassy
All pump & Compressor, Filter Head Group, All pump & Compressor, Filter Head Group, Corrosion Resistor
FIP
WIP Turbo & Mechanism Room
WIP
Disassy FIP, T/C, Mech. Valve
Washing
Primer Painting
10 Machining
1
1
1
1
1
1
2,5
5,55
5,55
4,44
4,3
6
42
3
3
3
3
3
6
6
6
9
8,76
9
9
36
33
6
42
1
1
1
1
1
1
1
1
2
3
2,92
3
3
6
5,5
Engine Washing
Prewash
Deep Tank 5500Ltr
Robowash Water
Robowash Chemical
Anti Rust Area
Sandering Area
WIP After Washing
Prepare Painting
Preparation Painting Block
Block & Others Primer Painting Room
Block Cleaning & Washing (Robowash Block)
Block Surface Grinding
Lathe machine for Axle Tube
Metal spray room
1
2
2
2
2
2
1
1
1
1
1
1
2
1
1
34,05
3
5
3
3
3
8
5
6
5
12
8
8
8,025
5,9
Preparation & Measurement Block
1
Block Cutting Protrution
Line Boring Machine
1
1
WIP Machining Block, Diff. house
Magnaflux
Wip Axle Tube
Conrod Machine
7
6
Equipment
p
l
L
Nama
Tools
p
l
L
Nama
2,075 70,6538
9
3
15
3
9
3
9
3
3
9
5
40
7,08
35,4
5
30
7,08
35,4
5,2
62,4
6
48
6
48 Surface Grinding Machine
48,15 Lathe Machine Big
6
6
35,4 Metal Spray
Lathe Machine 02
5,5
33
11 Assembly Station
l
L
Nama
p
l
L
p
4
l
3,25
L
13
Allowance
Luas-(Engine atau Mesin) Total
3,74506
9,25494
Valve Grinding
Deep Tank 3000
Spray Wash machine Apollo SWE800
After cooler tester
Oil Cooler Cleaner
0,4
1
0,4
1,2
2
2,4
0,4
2
1,2
1,8
1,7
1,3
0,65
0,5
1,56
1,17
0,85
2
2,1
4,2
1,56
2,64
Turbo Balancer
Cylinder Head tester 1
Cylinder Head Tester 2
Hyd Press Stand
Hyd Press Stand
Thermostat Tester
Deep Tank 3000
Spray Wash machine Apollo SWE800
Deep Tank 3000
Spray Wash machine Apollo SWE800
1,4
1,55
1,55
1,25
1,25
0,51
0,75
1,25
1,25
0,6
0,6
0,26
1,05
1,9375
1,9375
0,75
0,75
0,1326
2,5
2,5
2,5
2
2
0,8
2,5
2,1
2,1
1,1
1,1
0,8
6,25
5,25
5,25
2,2
2,2
0,64
1,05
1,9375
1,9375
0,75
0,75
0,1326
5,2
3,3125
3,3125
1,45
1,45
0,5074
1,3
1,3
1,69
2,15
215
462,25
1,69
460,56
1,2
1,3
1,56
2
2,1
4,2
1,56
2,64
Abrasive Blasting
2,75
1
2,75
2,75
1,9
5,225
2,75
2,475
FIP testbench
FIP tester
3,15
3,15
1,8
1,3
5,67
4,095
4,25
4,25
3,5
3
14,875
12,75
5,67
4,095
9,205
8,655
Deeptank 5500
Spray Wash Machine Apollo
Spray Wash Machine Apollo
3,05
2,45
2,45
2,32
2,62
2,62
7,076
6,419
6,419
4
3,9
3,3
3,3
3,25
3,2
3,5
3,5
13
12,48
11,55
11,55
3,74506
7,076
6,419
6,419
9,25494
5,404
5,131
5,131
6,83
8
1
2,9
1,4
2,2
0,65
1,15
SWE800 Spray Machine
1,2
1,3
1,56
Hyd Press Stand 25T
1,1
1,3
1,43
2
7,75
9
2,65
4,6
1,3
2,6
2,1
2,25
3,5
1,5
2,85
1,65
2,1
4,2
17,4375
31,5
3,975
13,11
2,145
5,46
1,56
9,562
17,6
0,65
3,335
1,43
0,405
2,64
7,8755
13,9
3,325
9,775
0,715
5,055
12,315
10,555
9,562
17,6
0,65
3,335
Hytorc Wrench
4
5,47
21,88
11
5,47
60,17
1
1
1
1
7,4
2,5
2,5
5,47
5,5
5,5
40,478
13,75
13,75
5
4,5
22,5
Conrod Alignment Tool
Crankshaft Grinding
1
2
WIP Crankshaft & Cam Shaft polish
Fabrication Room
1
1
5
7,5
7,5
7
4,5
4,5
4,5
4,5
6
13,9
WIP Fabrication
2
Receive Out House
Send Out House
Office Machining, fabrication, & Lab.
1
1
1
Milling & Lathe Machine
1
4,61
4,5
3,6
3,2
4,5
Electricity
p
1,5
3,75
2,25 12,4875
2
11,1
6,1 27,084
2,9
12,47
7
Deep Tank
Robowash Water
Prewash
Sandering Area
Sand Blasting room
WIP FIP Room
FIP Assembly Room
FIP Test Room
Mesin
Nama
Line Boring Machine
Line Boring Machine
Conrod Machine
22,5
33,75 Crankshaft Grinding Machine 1
33,75 Crankshaft Grinding Machine 2
31,5 Polish Machine
Drill Machine
83,4
4,473
3,473
1,35
7,428
9,514
2,65
0,9
10,1
19,7
4
4
4
4
4
4
4
4
4
4
1,5
4
4
4
4
6
12
20
15,69
4
11,98
59,5
4
11
4
4
13
7
5
5
6
5
5
10
5
3,83
3,83
3,83
3,83
3,83
3,83
3,83
3,83
2,2
2,2
1,5
2,2
2,2
3,74
3,74
6
6
6
6
6
7,6
3,5
4
6
6
6
6
6
6
6
6
6
6
6
6
Short Block 1
Short Block 2
Short Block 3
Short Block 4
Short Block 5
Short Block 6
Short Block 7
Short Block 8
Preparation Area
Liner & O ring Assembly
Liner wash
Crankshaft cleaning & measure
Piston & conrod preparation
Oil pump & strainer preparation
Parts prepare & tools area
Marking Area
WIP shortblock
WIP after painting
WIP Subassy
General Assy station
RFU ShortBlock
Preparation Line
Station
RFU Oil Pan F/W housing & Flywheel Gear Case & Cover
Oil Pump & Piston Cooling Nozzle Assembling
Oil Cooler & Cam follower Assembling
Cylinder Head Exhaust Manifold Assembling
Cross Head & Pulley Group Damper Assembling
Rocker Arm Push Rod Starting Motor Assembling
Water Pump Corrosion resistor Assembling
Intake Manifold & Heater After Cooling Assembling
Turbocharger Assembling
Filter Head Oil, Air Compressor, and Fuel Filter Head Assemb
Muffler, Air Cleaning Housing, Heat Shield, Fan
Alt. drive, Alternator Assembling
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
5
1
1
14
11
1
1
1
1
1
1
1
1
1
1
1
6,25
5,25
2,5
2,5
15,625
13,125
3,31002
2,57002
1,6
6,08
4,6
2,5
11,5
6,08
1,1
5,42
SWE800 Spray Machine
1,2
1,3
1,56
3
2
2,75
2,1
8,25
4,2
1,485
1,56
6,765
2,64
9,2
11,2
4,3
2,6
2,1
2,5
3,9
3,9
2,3
2,6
2,1
2,25
35,88
43,68
9,89
6,76
4,41
5,625
16,67586
21,35893
1,4575
0,81
0,175
0,54
19,2041
22,3211
8,4325
5,95
4,235
5,085
3,5
3,25
4,15
5
3,9
4,1
5,4
4
4
4
4
4
4
4
4
3,5
2,85
3,55
2,9
2,6
2,8
3,2
3,25
3,25
3,25
3,25
3,25
3,25
3,25
3,25
12,25
9,2625
14,7325
14,5
10,14
11,48
17,28
13
13
13
13
13
13
13
13
3,0625
1,65
4,655
4,02
2,25
2,585
5,55
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
9,1875
7,6125
10,0775
10,48
7,89
8,895
11,73
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
3,65
3,15
11,4975
2,9
8,5975
1,485
2,245 16,6759
2,245 21,3589
0,55 1,4575
0,9
0,81
0,5
0,9
1,1
0,35
0,6
1,3
0,175
0,54
1,43
Wiring Harness Sensor Assembling
1
4
6
12 Dyno Test
Dyno Test Preparation
Dyno Test
Engine Completed
1
5
1
15,425
6
14,4
5
7
5
24
0
77,125
42
72
13 Finishing
Masking & Preparation Before Painting
Assembly Painting Room
Wrapping Area
RFU Assembly
1
1
1
1
6
8
4
18,2
7
7
7
5
42
56
28
91
14 Warehouse
Warehouse ALB Preparation
Warehouse
1
1
26
34
CMM Portable
Roughness Tester
1,75
1,1
1,9
1,2
1
1,1
1,5
15,31 398,06
15,28 610,198
1,8
2,4
1,8
0,6
3,24
1,44
3,0625
1,65
4,655
4,02
2,25
2,585
5,55
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
8,8
8,8
8,8
14,96
14,96
36
72
120
94,14
24
91,048
208,25
16
66
24
24
78
42
30
30
36
30
30
60
30
0,405
3,8
ARC Welding 1
ARC Welding 2
Hyd Press Stand 25T
1,75
1,5
2,45
3,35
2,25
2,35
3,7
0,45
Magnaflux detector
3,97 18,3017
12
54
4,6
16,56
4,6
14,72
8
36
Milling Machine 1
Milling Machine 2
Milling Machine 3
189
Lathe Machine 1
Lathe Machine 3
Lathe Machine 4
0 Lathe Machine 5
15,32
15,32
15,32
15,32
15,32
15,32
15,32
15,32
8,8
0,9
0,74 3,31002
0,74 2,57002
Hyd Press Stand 25T
1,1
1,3
Drive
Drive
Drive
Drive
Drive
Drive
Drive
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,45
0,45
0,45
0,45
0,45
0,45
0,45
0,405
0,405
0,405
0,405
0,405
0,405
0,405
1,43
Starting Motor testbench
1,22
1,1
1,342
3
2,85
8,55
1,342
7,208
Alternator Testbench1
Alternator testbench2
1,15
1,35
0,85
1,06
0,9775
1,431
2,85
3
2,5
2,75
7,125
8,25
0,9775
1,431
6,1475
6,819
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disassy line
Customer inspection
Valve seat
Oil & After cooler
Pulley & drives
All pump and compressor
FIP
Washing
Primer painting
Machining
Assembly station
Dyno test
Finishing
Warehouse
LAMPIRAN 2
LAYOUT KESELURUHAN YANG TELAH MENGALAMI PERUBAHAN LUAS AREA
GARDEN
20 sq. m.
MECHANIC REST STAGE
20 sq. m.
TOILET
21 sq. m.
MECHANIC REST STAGE
33 sq. m.
GARDEN
12 sq. m.
TOILET
18 sq. m.
MECHANIC REST STAGE
42 sq. m.
PAINT
COLLECTOR
GARDEN
14 sq. m.
GARDEN
21 sq. m.
GARDEN
14 sq. m.
MECHANIC REST STAGE
33 sq. m.
TOILET
14 sq. m.
COOLING DYNO
44 sq. m.
GARDEN
11 sq. m.
GARDEN
12 sq. m.
OIL
TRAP
GARDEN
28 sq. m.
18 sq. m.
42 sq. m.
Wrapping
Area
28 sq. m.
398 sq. m.
56 sq. m.
WAREHOUSE
ALB PREPARATION
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
91 sq. m.
Engine
Completed
ALLOWANCE
ENGINE
sq.
m.
RFU ASSY
ALLOWANCE
ENGINE 72
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
½ T, 5.5m
FILTER HEAD OIL
TURBOCHARGER AIR COMPRESSOR
ASSEMBLING
FUEL FILTER HEAD
ASSEMBLING
30 sq. m.
30 sq. m.
Altern
ator
ALLOWANCE
testbe
nch 1
MUFFLER
AIR CLEANER HOUSING
HEAT SHIELD
FAN
60 sq. m.
ALT. DRIVE WIRING HARNESS
ALTERNATOR
SENSOR
ASSEMBLING
Alterna
ASSEMBLING
tor
ALLOWANCE
testben
ch
2 sq. m.
30
24 sq. m.
Tool & Equipment
Spare Part
Main
80 Storage
sq. m.
WIP
AFTER PAINTING
120 sq. m.
13DUST
sq. m.
COLLECTOR
17DUST
sq. m.
COLLECTOR
½ T, 5 m
Roller
Conv.
Ball
Conv.
OHC 10T
ALLOWANCE
ENGINE
General Assy
Station
General Assy
Station
General Assy
Station
General Assy
Station
24 sq. m.
24 sq. m.
24 sq. m.
24 sq. m.
KOPERASI
40 sq. m.
Consumable Good
Counter
4.0m.
Preparation
Painting
Block
35 sq. m.
TOILET
OIL
TRAP
GARDEN
M
AL
O
LO
S
WA
T
A
NC
T
E
WIP
AFTER WASHING
ROBOWASH
Sand Blasting
DEEP
Sandering AreaALLOWAN
SPRAY
WATER
ROOM
WASH
9
sq. m.
9 sq. m.
CE
TANK
WATER
SWE80
9 sq. m. 6 sq. m.
0
35 sq. m.
ALL PUMP & COMPRESSOR
FILTER HEAD GROUP
CORROSION RESISTOR
1 sq. m.
11 sq. m.
DIS ASSY
T
E
S
T
E
R
27 sq. m.
MINI
LAT
HE
SPRAY
WASH
Disassy
Line
18 sq. m.
ROLLER
2 sq. m.
Disassy
Line
12 sq. m.
PULLEY & DRIVES
ALLO
HYD
ROBOWASH
WANC
4 sq. m.
DIS ASSY
PRESS
OIL & AFTER COOLER
3 sq. m.
DIS ASSY
After Cooler
Tester
Oil Cooler
3 Cleaner
sq. m.
Disassy
Line
18 sq. m.
Block & Others
Primer Painting
ROOM
62 sq. m.
GARDEN
PAINT
COLLECTOR
Disassy
Line
18 sq. m.
Consumable
Goods
Main Storage
18 sq. m.
Preparation
Line
16 sq. m.
Preparation
Line
16 sq. m.
15 sq. m.
Customer
Inspection
HYT
ORC
DRIV
E
56 sq. m.
TRA
CEA
BILI
TY
TOO
LS
Disassy
ALLOWANCE
ENGINE
Line
40 sq. m.
Document Storage
18 sq. m.
Preparation
Line
16 sq. m.
1.7m.
12 sq. m.
STAND
E
25T
Disassy
Line
18 sq. m.
Preparation
Line
16 sq. m.
VALVE
18 sq. m.
1 sq. m.
Disassy
Line
18 sq. m.
2T, 5.5 m
DISASSY
5 sq. m.
GRINDIN
ALLOWAN
G
CE
WATER
ROBOWASH
ALLOWAN
SWE80
0 CE
WATER
4 sq. m.
WIP
PRE
WASH
9 sq. m.
COIL HEATER
HYD
ALLO
PRES
WAN
S
CE
STAN
D 25T
ENGINE
WASHING
Block
Cleaning
& Washing
(Robowash Block)
48 sq. m.
SPRAY
ALLOWAN
WASH
CE
WATER
SWE80
0
MECHANIC REST STAGE
R
SWE800
SPRING
TESTER
2T, 5.5m
36 sq. m.
VALVE SEAT
CUTTER
OHC 10 T
33 sq. m.
DEEP
TANK
9 sq. m.
2T, 5.5 m
WIP FIP
ROOM
VALVE SEAT
ROLLER REMOVE
MEASUREMENT
3 sq. m. 2 sq. m.
4 sq. m.
Prepare Painting
30 sq. m.
TOILET
GARDEN
12 sq. m.
21 sq. m.
120.0m.
128.0m.
Sandering Area
40 sq. m.
MECHANIC REST STAGE
37 sq. m.
ROBOWASH
ROBOWASH
SPRAY
SPRAY
WASH
WASH
WATER
ANTI RUST CHEMICAL
WATER
WATER
SWE1612
SWE1612
12 sq. m.
12 sq. m.
9AREA
sq. m.
GARDEN
11 sq. m.
TOILET
21 sq. m.
DEEP
DEEP
TANK
5500
LT
TANK
12 sq. m.
GARDEN
16 sq. m.
ENGINE
PRE
WASH
13 sq. m.
OIL
TRAP
HIGH
PRESSUR
E WATER
BLASTER
ROBOWASH
SPRAY
ROBOWASH
SPRAY
WASH
WASH
WATER
ANTI RUST CHEMICAL
WATER
WATER
SWE1612
SWE1612
12 sq. m.
12 sq. m.
9AREA
sq. m.
MECHANIC REST STAGE
30 sq. m.
DEEP TANK
DEEP
5500
LT
12TANK
sq. m.
GARDEN
21 sq. m.
GA
Storage
64 sq. m.
OHC 2 T
Block Surface Grinding
2
48 sq. m.
SURFACE GRINDING MACHINE
BIG LATHE MACHINE
GARDEN
FIP Assembly
ROOM
2.0m.
Block Surface Grinding
1
48 sq. m.
SURFACE GRINDING MACHINE
40 sq. m.
CYLIND
ER
Tur
HEAD
bo
TESTE
Bal
3 sq. m. ALLOWANCE
ALLOWANCE
R 1DIS ASSY
anc
DEEP
er
MECH. VALVEWIP TURBO &
TANKFIP, T/C,
CYLIND
ER
MECHANISM
ROBOWASH HEAD
T
ALLOWAN
SPRAY
ROOM
ALLOWANCE
WATER
HTESTE
CE m.
WASH
E R2
2WATER
sq.
42 sq. m.
Abrasive
Blasting
Allowance
Preparation &
Measurement
HYT
ALLO
ORBlock
HYD
WANC
C
PRESS
ALLOWANCE
E
WR
33 sq. m. STAND
25T
EN
CH
22 sq. m.
2T, 5.5 m
54 sq. m.
2T, 5.5m
2T, 5.5 m
LATHE
ALLOWANCE
MACHINE 2
GARDEN
Station
14
16 sq. m.
ALLOWANCE
ENGINE
OHC 2 T
LINE BORING
MACHINE
Block
Cutting
Protrution
42
SIN
K
sq.FILm.
TER
CAT
2.0m.
O2,ACC
GAS
ROOM
Lathe Machine
For Axle Tube
Metal Spray
Room
30 sq. m.
Station
13
16 sq. m.
Station
ALLOWANCE
ENGINE
CONVEYOR
12
16 sq. m.
2T, 5.5 m
2X FIPSOL
TEST
VE
ROOM
NT
OD
ALLOWANCE
MACHI
1.8m.
LINE BORING MACHINE
Line Boring Machine
2
60 sq. m.
40 sq. m.
MET
AL
SPR
AY
HYD
PRESS
STAND
25T
40 sq. m.
Station
11
16 sq. m.
ALLOWANCE
ENGINE
General Assy
Station
5.5 m, 1/2 T
23 sq. m.
NE
83 sq. m.
DRI
LL
ALLOWANCE
MA
CHI
NE
Station
10
16 sq. m.
ALLOWANCE
ENGINE
2.5m.
CONROD
CONR
MACHINE
23 sq. m.
FIP
Allowance
Tester
CONROD
ALLIGNMENT TOOL
FIP Allowance
Testbench
WIP Crankshaft
& Cam Shaft Polsh
POLISH
MACHINE
CrankShaft Grinding
CRANKSHAFT GRINDING 2
2
50 sq. m.
Block, Diff House
Fabrication
Room
2
Station
9
16 sq. m.
ALLOWANCE
ENGINE
WIP SUB ASSY
94 sq. m.
SPRAY
WASH
WATER
ALLOWAN
SWE80
0 CE
2T, 5.5 m
OHC 5 T
CrankShaft
Grinding
CRANKSHAFT GRINDING
1
1
41 sq. m.
VERTICAL BORING
A
R
C
W
ALLOWAN
EL
CE
DI
N
G
1
ALLOWANCE
ENGINE
HYD
14 sq. m.
2 T, 5.5 m
M. FLUX
WIP Machining
ARC
Station
8 m.
16 sq.
ALLOWANCE
ENGINE
24 sq. m.
2T, 5.5 m
WEL
ALLOWANCE
DING
112 sq. m.
Station
7 m.
16 sq.
Station
6 m.
16 sq.
ALLOWANCE
ENGINE
HYD
MAGNAFLUX
WIP
AXLE
TUBE
WIP
Fab
18 sq. m.
Roller
Conv.
2.4m.
WIP
Short Block
72 sq. m.
MARKING
AREA
36 sq. m.
Station
5 m.
16 sq.
ALLOWANCE
ENGINE
6.1m.
2 T, 5.5 m
2.2m.
Station
ALLOWANCE
ENGINE
4 m.
16 sq.
PRESS
ALLOWAN
STAND
CE
Send
Out
House
15 Fab
sq. m.
ALLOWANCE
ENGINE
PRESS
ALLOWAN
STAND
CE
Receive
Out
House
17 Fab
sq. m.
Station
3 m.
16 sq.
Station
2 m.
16 sq.
ALLOWANCE
ENGINE
1/2 T, 5.5 m
3.0m.
2T, 5.5 m
OFFICE
Station
ALLOWANCE
16ENGINE
sq.
1 m.
5 m, ½ T
Piston &
ConRod
Preparation
9 sq. m.
C/ Shaft
Cleaning
Measure
9 sq. m.
Short Block 1
Install
Bushing &
ALLOWANCE
ENGINE
Plug
15 sq. m.
Block
Liner & Oring
Preparation
Liner
Assembly
Area
Wash.
9 sq. m.
9 sq. m.
2 sq. m.
Short Block 2
Install
Liner
ALLOWANCE
ENGINE
15 sq. m.
Preparation
Line
208 sq. m.
5 m, ½ T
Short Block 3
C/ENGINE
Shaft
ALLOWANCE
15 sq. m.
2T, 5.5 m
Short Block 4
Piston &
ALLOWANCE
ENGINE
ConRod
15 sq. m.
3.0m.
Up
RFU
Short Block
91 sq. m.
OHC 5T
2 T, 5.5 m
LATHE
ALLOWANCE
MACHINE 5
36 sq. m.
OFFICE
ROUGHNES
S TESTER
MACHINING/FAB.
& Lab
(office Lt 2
Lab Lt 1)
Parts Prepare
& Tools
Area
15 sq. m.
Short Block 6
Short Block 5
Short Block 7
Fly/W Housing, Gear Case
Short Block 8
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
Oil
Pump &
Timing
Gear
FIP Drive, Cam Shaft
Front Cover
Strainer
Assy & Measure
Oil Pan
15 sq. m.
15 sq. m.
15 sq. m.
15 sq. m.
MILLING & LATHE
LATHE
ALLOWANCE
MACHINE
MACHINE 4
MILLING
ALLOWANCE
MACHINE 3
CMM
PORTAB
LE
Parts Prepare
& Tools
Area
15 sq. m.
½ T, 5 m
54 sq. m.
Parts Prepare
& Tools
Area
15 sq. m.
½ T, 5 m
15 sq. m.
½ T, 5 m
MACHINE 3
2 T, 5.5 m
Oil Pump &
Strainer
Preparation
LATHE
189 sq. m.
ALLOWANCE
12 sq. m.
LATHE
ALLOWANCE
MACHINE 1
12 sq. m.
MILLIN
G
ALLOWANCE
MACHI
NE 2
WIP
Fab
2.5m.
30 sq. m.
MILLING
ALLOWANCE
MACHIN
E1
ENGINE
PRE
WASH
13 sq. m.
OIL
TRAP
GARDEN
8 sq. m.
TOILET
11 sq. m.
GARDEN
8 sq. m.
66.0m.
78 sq. m.
40 sq. m.
ALLOWANCE
ENGINE
60.0m.
24 sq. m.
ARM
INTAKE MANIFOLD
WATER PUMP
PUSH ROD
HEATER
CORROSION RESISTOR
ST. MOTOR
AFTER COOLER
ASSEMBLING
ASSEMBLING
ASSEMBLING
30 sq. m.
30 sq. m.
36 sq. m.
½ T, 5.5 m
24 sq. m.
Startin
g
ALLOWANCE
motor
testbe
ROCKER
nch
CROSS HEAD
PULLEY GROUP
DAMPER
ASSEMBLING
42 sq. m.
CYLINDER HEAD
& EXHAUST MANIFOLD
ASSEMBLING
MAINTENANCE
ROOM
DYNO TEST
PREPARATION
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
77 sq. m.
½ T, 5.5 m
OIL PUMP &
OIL COOLER &
PISTON
CAM FOLLOWER
COOLING NOZZLE
ASSEMBLING
ASSEMBLING
½ T, 5.5 m
66 sq. m.
½ T, 5.5 m
RFU
OIL PAN
F/W HOUSING & FLYWHEEL
GEAR CASE & COVER
91 sq. m.
40 sq. m.
Compressor
Room
40 sq. m.
6.0m.
WAREHOUSE
Compressor
Tanks
42 sq. m.
OHC 10 T
OHC 5 T
WAREHOUSE
Masking &
Preparation
Before
Painting
ASSY’ PAINTING
ROOM
3.2m.
519 sq. m.
3.3m.
Receiving
Parts
KESIMPULAN DAN SARAN
6.1. Kesimpulan
Berdasarkan hasil evaluasi dari rancangan tata
letak fasilitas baru plant 1
plant
3
PT.
Komatsu
yang akan dibangun di
Remanufacturing
Asia
didapatkan
bahwa tidak ada masalah dengan aliran material (flow)
dan
kegiatan
fasilitas
(activity)
baru
keleluasaan
departemen
plant
area
yang
3
pada
rancangan
tersebut.
(space)
mengalami
tata
Namun,
terdapat
letak
dari
beberapa
ketidakcukupan
area
sisi
subdalam
peletakan mesin maupun ketidakleluasaan area kerja bagi
operator.
Sub-departemen
–
sub-departemen
tersebut
adalah:
a. Departemen washing
1. Prewash
2. Deep tank
3. Robowash water
4. Robowash chemical
b. Departemen machining
1. Crankshaft grinding 1
2. Crankshaft grinding 2
3. Lathe machine for axle tube
Rancangan
dinyatakan
terhadap
tata
layak
letak
dengan
fasilitas
melakukan
sub-departemen
–
baru
ini
dapat
perluasan
area
sub-departemen
yang
disebutkan di atas. Perluasan area ini akan berdampak
terhadap
ukuran
beberapa
sekitar
sub-departemen
sub-departemen
yang
yang
mengalami
ada
di
perluasan
tersebut. Hal ini dikarenakan perusahaan sudah tidak
130
dapat
memberikan
perluasan
area
secara
keseluruhan,
sehingga yang dapat dilakukan adalah mengurangi luas
area sub-departemen yang masih berlebih.
Sub-departemen
yang
mengalami
dampak
akibat
perluasan area sub-departemen di atas adalah :
a. WIP crankshaft and camshaft
b. Line boring machine
c. Magnaflux
d. WIP axle tube
e. Metal spray room
6.2. Saran
Saran yang dapat diberikan sebagai bahan masukan
bagi perusahaan antara lain :
a. Sistem penanganan material untuk memindahkan engine
dari overhead crane yang berkapasitas 5 ton dan 10
ton hendaknya dipertimbangkan dengan sebaik-baiknya,
karena
crane
apabila
ini
pemindahan
terhambat,
maka
engine
akan
antar
overhead
menghambat
aliran
produksi secara keseluruhan.
b. Pergantian tata letak fasilitas di sub-departemen
assembly
yang
semula
berupa
workstation
terpusat
menjadi lintasan lini seperti yang dicita-citakan
perusahaan hendaknya dilaksanakan setelah masalahmasalah yang dapat menghambat kelancaran berjalannya
lintasan lini dapat teratasi. Berdasarkan pengamatan
penulis,
masalah-masalah
yang
dapat
menghambat
kelancaran berjalannya lintasan lini tersebut antara
lain :
1. Keterlambatan spare part
Masalah
ini
dapat
diatasi
dengan
memperbaiki
sistem inventory dan production planning control.
131
2. Pekerja yang kurang terampil dalam merakit engine
sehingga menyebabkan terjadinya redo (bongkar dan
pasang kembali)
Masalah
ini
dapat
diatasi
dengan
memberikan
training atau pelatihan kepada pekerja mengenai
proses perakitan engine.
3. Kurang
lengkapnya
alat
yang
digunakan
dalam
proses perakitan
Masalah ini dapat diatasi dengan melengkapi alatalat
yang
pekerjaannya
digunakan
tidak
ketidaktersediaan alat.
132
oleh
pekerja
terhambat
sehingga
karena
DAFTAR PUSTAKA
Apple, J.M, 1990, Tata Letak Pabrik dan Pemindahan
Bahan, Institut Teknologi Bandung, Bandung.
Assauri,S., 1977, Manajemen Produksi, Lembaga Penerbit
Fakultas Ekonomi, Universitas Indonesia, Jakarta.
Daryanto, Y, 2003, Perencanaan Tata Letak Fasilitas
Produksi
Berdasarkan
Group
Technology
dengan
Metode Non Linear and Assignment Allocation
Algorithm (Studi Kasus di PT. Swasti Pandawa
Armada, Magelang), Program Studi Teknik Industri,
Fakultas Teknologi Industri, Universitas Atma Jaya
Yogyakarta, Yogyakarta.
Dasi,
P.M.K.D, 2008, Usulan Perancangan Ulang Tata
Letak Fasilitas (Studi Kasus di CV. Pandanus
Internusa, Yogyakarta), Skripsi, Program Studi
Teknik Industri, Fakultas Teknologi Industri,
Universitas Atma Jaya Yogyakarta, Yogyakarta.
Kurniawan, A.A., 2007, Perancangan Ulang Tata Letak
Fasilitas Produksi (Studi Kasus di PT Prestige
Furniture,
Yogyakarta),
Program
Studi
Teknik
Industri, Fakultas Teknologi Industri, Universitas
Atma Jaya Yogyakarta, Yogyakarta.
Lee,
Q., Arild Amundsen, William Nelson, Herbert
Tuttle., 1996, facilities and Workplace Design,
Engineering and Management Press Institute of
Industrial Engineers Norcross Georgia, USA.
Meyers, Fred E dan Stephens, Matthew P., 2005,
Manufacturing
Facilities
Design
and
Material
Handling, 3rd Ed, Prentice Hall, Inc., New Jersey.
Muther, Richard., 1970, Plant Layout and Design,
Handbook of Modern Manufacturing Management, Mc
Graw Hill.
133
Satria, 2007, Plant Layout / Facilities Layout,
Http://www.bysatria.wordpress.com/2007/03/11/plant
-layout-facilities-layout/-20k-, diakses 25 April
2009.
Tompkins, James A., White, John A., Bozer, Yavus A.,
dan Tanchocho, J.M.A., 2003, Facilities Planning,
3th Ed, John Wiley & Sons, Inc., United States of
America.
Wignjosoebroto, S., 2003, Tata Letak Pabrik dan
Pemindahan Bahan, Edisi Ketiga, PT. Guna Widya,
Jakarta.
Yuniarti, A.T., 2009, Usulan Perancangan Tata Letak
Baru Akibat Perluasan Pabrik (Studi Kasus di PT.
Mega
Andalan
Kalasan,
Yogyakarta),
Skripsi,
Program Studi Teknik Industri, Fakultas Teknologi
Industri,
Universitas
Atma
Jaya
Yogyakarta,
Yogyakarta.
134
LAMPIRAN 1
No.
Departemen
1
2
3
Disassy Line
Customer Inspection
Valve Seat
4
Oil & After Cooler
5
6
7
8
9
Nama sub-departemen
Disassy Line
Customer Inspection
Disassy
Roller
Roller
Measurement
Valve seat remove
Deep Tank
Robowash Water
Oil & After Cooler Disassy
Jumlah sub-Ukuran sub-departemen (m2)
departemen
p
l
L
7
4
4,5
18
1
4
4,5
18
1
4,5
1
4,5
2
1
2
2
3,2
1
3,2
1
3,95
1
3,95
1
1,5
1,5
2,25
1
3,5
2,5
8,75
1
2
2
4
1
5
3
15
Robowash
Pulley & Drives
Pulley & Drives Disassy
All pump & Compressor, Filter Head Group, All pump & Compressor, Filter Head Group, Corrosion Resistor
FIP
WIP Turbo & Mechanism Room
WIP
Disassy FIP, T/C, Mech. Valve
Washing
Primer Painting
10 Machining
1
1
1
1
1
1
2,5
5,55
5,55
4,44
4,3
6
42
3
3
3
3
3
6
6
6
9
8,76
9
9
36
33
6
42
1
1
1
1
1
1
1
1
2
3
2,92
3
3
6
5,5
Engine Washing
Prewash
Deep Tank 5500Ltr
Robowash Water
Robowash Chemical
Anti Rust Area
Sandering Area
WIP After Washing
Prepare Painting
Preparation Painting Block
Block & Others Primer Painting Room
Block Cleaning & Washing (Robowash Block)
Block Surface Grinding
Lathe machine for Axle Tube
Metal spray room
1
2
2
2
2
2
1
1
1
1
1
1
2
1
1
34,05
3
5
3
3
3
8
5
6
5
12
8
8
8,025
5,9
Preparation & Measurement Block
1
Block Cutting Protrution
Line Boring Machine
1
1
WIP Machining Block, Diff. house
Magnaflux
Wip Axle Tube
Conrod Machine
7
6
Equipment
p
l
L
Nama
Tools
p
l
L
Nama
2,075 70,6538
9
3
15
3
9
3
9
3
3
9
5
40
7,08
35,4
5
30
7,08
35,4
5,2
62,4
6
48
6
48 Surface Grinding Machine
48,15 Lathe Machine Big
6
6
35,4 Metal Spray
Lathe Machine 02
5,5
33
11 Assembly Station
l
L
Nama
p
l
L
p
4
l
3,25
L
13
Allowance
Luas-(Engine atau Mesin) Total
3,74506
9,25494
Valve Grinding
Deep Tank 3000
Spray Wash machine Apollo SWE800
After cooler tester
Oil Cooler Cleaner
0,4
1
0,4
1,2
2
2,4
0,4
2
1,2
1,8
1,7
1,3
0,65
0,5
1,56
1,17
0,85
2
2,1
4,2
1,56
2,64
Turbo Balancer
Cylinder Head tester 1
Cylinder Head Tester 2
Hyd Press Stand
Hyd Press Stand
Thermostat Tester
Deep Tank 3000
Spray Wash machine Apollo SWE800
Deep Tank 3000
Spray Wash machine Apollo SWE800
1,4
1,55
1,55
1,25
1,25
0,51
0,75
1,25
1,25
0,6
0,6
0,26
1,05
1,9375
1,9375
0,75
0,75
0,1326
2,5
2,5
2,5
2
2
0,8
2,5
2,1
2,1
1,1
1,1
0,8
6,25
5,25
5,25
2,2
2,2
0,64
1,05
1,9375
1,9375
0,75
0,75
0,1326
5,2
3,3125
3,3125
1,45
1,45
0,5074
1,3
1,3
1,69
2,15
215
462,25
1,69
460,56
1,2
1,3
1,56
2
2,1
4,2
1,56
2,64
Abrasive Blasting
2,75
1
2,75
2,75
1,9
5,225
2,75
2,475
FIP testbench
FIP tester
3,15
3,15
1,8
1,3
5,67
4,095
4,25
4,25
3,5
3
14,875
12,75
5,67
4,095
9,205
8,655
Deeptank 5500
Spray Wash Machine Apollo
Spray Wash Machine Apollo
3,05
2,45
2,45
2,32
2,62
2,62
7,076
6,419
6,419
4
3,9
3,3
3,3
3,25
3,2
3,5
3,5
13
12,48
11,55
11,55
3,74506
7,076
6,419
6,419
9,25494
5,404
5,131
5,131
6,83
8
1
2,9
1,4
2,2
0,65
1,15
SWE800 Spray Machine
1,2
1,3
1,56
Hyd Press Stand 25T
1,1
1,3
1,43
2
7,75
9
2,65
4,6
1,3
2,6
2,1
2,25
3,5
1,5
2,85
1,65
2,1
4,2
17,4375
31,5
3,975
13,11
2,145
5,46
1,56
9,562
17,6
0,65
3,335
1,43
0,405
2,64
7,8755
13,9
3,325
9,775
0,715
5,055
12,315
10,555
9,562
17,6
0,65
3,335
Hytorc Wrench
4
5,47
21,88
11
5,47
60,17
1
1
1
1
7,4
2,5
2,5
5,47
5,5
5,5
40,478
13,75
13,75
5
4,5
22,5
Conrod Alignment Tool
Crankshaft Grinding
1
2
WIP Crankshaft & Cam Shaft polish
Fabrication Room
1
1
5
7,5
7,5
7
4,5
4,5
4,5
4,5
6
13,9
WIP Fabrication
2
Receive Out House
Send Out House
Office Machining, fabrication, & Lab.
1
1
1
Milling & Lathe Machine
1
4,61
4,5
3,6
3,2
4,5
Electricity
p
1,5
3,75
2,25 12,4875
2
11,1
6,1 27,084
2,9
12,47
7
Deep Tank
Robowash Water
Prewash
Sandering Area
Sand Blasting room
WIP FIP Room
FIP Assembly Room
FIP Test Room
Mesin
Nama
Line Boring Machine
Line Boring Machine
Conrod Machine
22,5
33,75 Crankshaft Grinding Machine 1
33,75 Crankshaft Grinding Machine 2
31,5 Polish Machine
Drill Machine
83,4
4,473
3,473
1,35
7,428
9,514
2,65
0,9
10,1
19,7
4
4
4
4
4
4
4
4
4
4
1,5
4
4
4
4
6
12
20
15,69
4
11,98
59,5
4
11
4
4
13
7
5
5
6
5
5
10
5
3,83
3,83
3,83
3,83
3,83
3,83
3,83
3,83
2,2
2,2
1,5
2,2
2,2
3,74
3,74
6
6
6
6
6
7,6
3,5
4
6
6
6
6
6
6
6
6
6
6
6
6
Short Block 1
Short Block 2
Short Block 3
Short Block 4
Short Block 5
Short Block 6
Short Block 7
Short Block 8
Preparation Area
Liner & O ring Assembly
Liner wash
Crankshaft cleaning & measure
Piston & conrod preparation
Oil pump & strainer preparation
Parts prepare & tools area
Marking Area
WIP shortblock
WIP after painting
WIP Subassy
General Assy station
RFU ShortBlock
Preparation Line
Station
RFU Oil Pan F/W housing & Flywheel Gear Case & Cover
Oil Pump & Piston Cooling Nozzle Assembling
Oil Cooler & Cam follower Assembling
Cylinder Head Exhaust Manifold Assembling
Cross Head & Pulley Group Damper Assembling
Rocker Arm Push Rod Starting Motor Assembling
Water Pump Corrosion resistor Assembling
Intake Manifold & Heater After Cooling Assembling
Turbocharger Assembling
Filter Head Oil, Air Compressor, and Fuel Filter Head Assemb
Muffler, Air Cleaning Housing, Heat Shield, Fan
Alt. drive, Alternator Assembling
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
5
1
1
14
11
1
1
1
1
1
1
1
1
1
1
1
6,25
5,25
2,5
2,5
15,625
13,125
3,31002
2,57002
1,6
6,08
4,6
2,5
11,5
6,08
1,1
5,42
SWE800 Spray Machine
1,2
1,3
1,56
3
2
2,75
2,1
8,25
4,2
1,485
1,56
6,765
2,64
9,2
11,2
4,3
2,6
2,1
2,5
3,9
3,9
2,3
2,6
2,1
2,25
35,88
43,68
9,89
6,76
4,41
5,625
16,67586
21,35893
1,4575
0,81
0,175
0,54
19,2041
22,3211
8,4325
5,95
4,235
5,085
3,5
3,25
4,15
5
3,9
4,1
5,4
4
4
4
4
4
4
4
4
3,5
2,85
3,55
2,9
2,6
2,8
3,2
3,25
3,25
3,25
3,25
3,25
3,25
3,25
3,25
12,25
9,2625
14,7325
14,5
10,14
11,48
17,28
13
13
13
13
13
13
13
13
3,0625
1,65
4,655
4,02
2,25
2,585
5,55
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
3,74506
9,1875
7,6125
10,0775
10,48
7,89
8,895
11,73
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
9,25494
3,65
3,15
11,4975
2,9
8,5975
1,485
2,245 16,6759
2,245 21,3589
0,55 1,4575
0,9
0,81
0,5
0,9
1,1
0,35
0,6
1,3
0,175
0,54
1,43
Wiring Harness Sensor Assembling
1
4
6
12 Dyno Test
Dyno Test Preparation
Dyno Test
Engine Completed
1
5
1
15,425
6
14,4
5
7
5
24
0
77,125
42
72
13 Finishing
Masking & Preparation Before Painting
Assembly Painting Room
Wrapping Area
RFU Assembly
1
1
1
1
6
8
4
18,2
7
7
7
5
42
56
28
91
14 Warehouse
Warehouse ALB Preparation
Warehouse
1
1
26
34
CMM Portable
Roughness Tester
1,75
1,1
1,9
1,2
1
1,1
1,5
15,31 398,06
15,28 610,198
1,8
2,4
1,8
0,6
3,24
1,44
3,0625
1,65
4,655
4,02
2,25
2,585
5,55
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
Hytorc
8,8
8,8
8,8
14,96
14,96
36
72
120
94,14
24
91,048
208,25
16
66
24
24
78
42
30
30
36
30
30
60
30
0,405
3,8
ARC Welding 1
ARC Welding 2
Hyd Press Stand 25T
1,75
1,5
2,45
3,35
2,25
2,35
3,7
0,45
Magnaflux detector
3,97 18,3017
12
54
4,6
16,56
4,6
14,72
8
36
Milling Machine 1
Milling Machine 2
Milling Machine 3
189
Lathe Machine 1
Lathe Machine 3
Lathe Machine 4
0 Lathe Machine 5
15,32
15,32
15,32
15,32
15,32
15,32
15,32
15,32
8,8
0,9
0,74 3,31002
0,74 2,57002
Hyd Press Stand 25T
1,1
1,3
Drive
Drive
Drive
Drive
Drive
Drive
Drive
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,45
0,45
0,45
0,45
0,45
0,45
0,45
0,405
0,405
0,405
0,405
0,405
0,405
0,405
1,43
Starting Motor testbench
1,22
1,1
1,342
3
2,85
8,55
1,342
7,208
Alternator Testbench1
Alternator testbench2
1,15
1,35
0,85
1,06
0,9775
1,431
2,85
3
2,5
2,75
7,125
8,25
0,9775
1,431
6,1475
6,819
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disassy line
Customer inspection
Valve seat
Oil & After cooler
Pulley & drives
All pump and compressor
FIP
Washing
Primer painting
Machining
Assembly station
Dyno test
Finishing
Warehouse
LAMPIRAN 2
LAYOUT KESELURUHAN YANG TELAH MENGALAMI PERUBAHAN LUAS AREA
GARDEN
20 sq. m.
MECHANIC REST STAGE
20 sq. m.
TOILET
21 sq. m.
MECHANIC REST STAGE
33 sq. m.
GARDEN
12 sq. m.
TOILET
18 sq. m.
MECHANIC REST STAGE
42 sq. m.
PAINT
COLLECTOR
GARDEN
14 sq. m.
GARDEN
21 sq. m.
GARDEN
14 sq. m.
MECHANIC REST STAGE
33 sq. m.
TOILET
14 sq. m.
COOLING DYNO
44 sq. m.
GARDEN
11 sq. m.
GARDEN
12 sq. m.
OIL
TRAP
GARDEN
28 sq. m.
18 sq. m.
42 sq. m.
Wrapping
Area
28 sq. m.
398 sq. m.
56 sq. m.
WAREHOUSE
ALB PREPARATION
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
91 sq. m.
Engine
Completed
ALLOWANCE
ENGINE
sq.
m.
RFU ASSY
ALLOWANCE
ENGINE 72
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
½ T, 5.5m
FILTER HEAD OIL
TURBOCHARGER AIR COMPRESSOR
ASSEMBLING
FUEL FILTER HEAD
ASSEMBLING
30 sq. m.
30 sq. m.
Altern
ator
ALLOWANCE
testbe
nch 1
MUFFLER
AIR CLEANER HOUSING
HEAT SHIELD
FAN
60 sq. m.
ALT. DRIVE WIRING HARNESS
ALTERNATOR
SENSOR
ASSEMBLING
Alterna
ASSEMBLING
tor
ALLOWANCE
testben
ch
2 sq. m.
30
24 sq. m.
Tool & Equipment
Spare Part
Main
80 Storage
sq. m.
WIP
AFTER PAINTING
120 sq. m.
13DUST
sq. m.
COLLECTOR
17DUST
sq. m.
COLLECTOR
½ T, 5 m
Roller
Conv.
Ball
Conv.
OHC 10T
ALLOWANCE
ENGINE
General Assy
Station
General Assy
Station
General Assy
Station
General Assy
Station
24 sq. m.
24 sq. m.
24 sq. m.
24 sq. m.
KOPERASI
40 sq. m.
Consumable Good
Counter
4.0m.
Preparation
Painting
Block
35 sq. m.
TOILET
OIL
TRAP
GARDEN
M
AL
O
LO
S
WA
T
A
NC
T
E
WIP
AFTER WASHING
ROBOWASH
Sand Blasting
DEEP
Sandering AreaALLOWAN
SPRAY
WATER
ROOM
WASH
9
sq. m.
9 sq. m.
CE
TANK
WATER
SWE80
9 sq. m. 6 sq. m.
0
35 sq. m.
ALL PUMP & COMPRESSOR
FILTER HEAD GROUP
CORROSION RESISTOR
1 sq. m.
11 sq. m.
DIS ASSY
T
E
S
T
E
R
27 sq. m.
MINI
LAT
HE
SPRAY
WASH
Disassy
Line
18 sq. m.
ROLLER
2 sq. m.
Disassy
Line
12 sq. m.
PULLEY & DRIVES
ALLO
HYD
ROBOWASH
WANC
4 sq. m.
DIS ASSY
PRESS
OIL & AFTER COOLER
3 sq. m.
DIS ASSY
After Cooler
Tester
Oil Cooler
3 Cleaner
sq. m.
Disassy
Line
18 sq. m.
Block & Others
Primer Painting
ROOM
62 sq. m.
GARDEN
PAINT
COLLECTOR
Disassy
Line
18 sq. m.
Consumable
Goods
Main Storage
18 sq. m.
Preparation
Line
16 sq. m.
Preparation
Line
16 sq. m.
15 sq. m.
Customer
Inspection
HYT
ORC
DRIV
E
56 sq. m.
TRA
CEA
BILI
TY
TOO
LS
Disassy
ALLOWANCE
ENGINE
Line
40 sq. m.
Document Storage
18 sq. m.
Preparation
Line
16 sq. m.
1.7m.
12 sq. m.
STAND
E
25T
Disassy
Line
18 sq. m.
Preparation
Line
16 sq. m.
VALVE
18 sq. m.
1 sq. m.
Disassy
Line
18 sq. m.
2T, 5.5 m
DISASSY
5 sq. m.
GRINDIN
ALLOWAN
G
CE
WATER
ROBOWASH
ALLOWAN
SWE80
0 CE
WATER
4 sq. m.
WIP
PRE
WASH
9 sq. m.
COIL HEATER
HYD
ALLO
PRES
WAN
S
CE
STAN
D 25T
ENGINE
WASHING
Block
Cleaning
& Washing
(Robowash Block)
48 sq. m.
SPRAY
ALLOWAN
WASH
CE
WATER
SWE80
0
MECHANIC REST STAGE
R
SWE800
SPRING
TESTER
2T, 5.5m
36 sq. m.
VALVE SEAT
CUTTER
OHC 10 T
33 sq. m.
DEEP
TANK
9 sq. m.
2T, 5.5 m
WIP FIP
ROOM
VALVE SEAT
ROLLER REMOVE
MEASUREMENT
3 sq. m. 2 sq. m.
4 sq. m.
Prepare Painting
30 sq. m.
TOILET
GARDEN
12 sq. m.
21 sq. m.
120.0m.
128.0m.
Sandering Area
40 sq. m.
MECHANIC REST STAGE
37 sq. m.
ROBOWASH
ROBOWASH
SPRAY
SPRAY
WASH
WASH
WATER
ANTI RUST CHEMICAL
WATER
WATER
SWE1612
SWE1612
12 sq. m.
12 sq. m.
9AREA
sq. m.
GARDEN
11 sq. m.
TOILET
21 sq. m.
DEEP
DEEP
TANK
5500
LT
TANK
12 sq. m.
GARDEN
16 sq. m.
ENGINE
PRE
WASH
13 sq. m.
OIL
TRAP
HIGH
PRESSUR
E WATER
BLASTER
ROBOWASH
SPRAY
ROBOWASH
SPRAY
WASH
WASH
WATER
ANTI RUST CHEMICAL
WATER
WATER
SWE1612
SWE1612
12 sq. m.
12 sq. m.
9AREA
sq. m.
MECHANIC REST STAGE
30 sq. m.
DEEP TANK
DEEP
5500
LT
12TANK
sq. m.
GARDEN
21 sq. m.
GA
Storage
64 sq. m.
OHC 2 T
Block Surface Grinding
2
48 sq. m.
SURFACE GRINDING MACHINE
BIG LATHE MACHINE
GARDEN
FIP Assembly
ROOM
2.0m.
Block Surface Grinding
1
48 sq. m.
SURFACE GRINDING MACHINE
40 sq. m.
CYLIND
ER
Tur
HEAD
bo
TESTE
Bal
3 sq. m. ALLOWANCE
ALLOWANCE
R 1DIS ASSY
anc
DEEP
er
MECH. VALVEWIP TURBO &
TANKFIP, T/C,
CYLIND
ER
MECHANISM
ROBOWASH HEAD
T
ALLOWAN
SPRAY
ROOM
ALLOWANCE
WATER
HTESTE
CE m.
WASH
E R2
2WATER
sq.
42 sq. m.
Abrasive
Blasting
Allowance
Preparation &
Measurement
HYT
ALLO
ORBlock
HYD
WANC
C
PRESS
ALLOWANCE
E
WR
33 sq. m. STAND
25T
EN
CH
22 sq. m.
2T, 5.5 m
54 sq. m.
2T, 5.5m
2T, 5.5 m
LATHE
ALLOWANCE
MACHINE 2
GARDEN
Station
14
16 sq. m.
ALLOWANCE
ENGINE
OHC 2 T
LINE BORING
MACHINE
Block
Cutting
Protrution
42
SIN
K
sq.FILm.
TER
CAT
2.0m.
O2,ACC
GAS
ROOM
Lathe Machine
For Axle Tube
Metal Spray
Room
30 sq. m.
Station
13
16 sq. m.
Station
ALLOWANCE
ENGINE
CONVEYOR
12
16 sq. m.
2T, 5.5 m
2X FIPSOL
TEST
VE
ROOM
NT
OD
ALLOWANCE
MACHI
1.8m.
LINE BORING MACHINE
Line Boring Machine
2
60 sq. m.
40 sq. m.
MET
AL
SPR
AY
HYD
PRESS
STAND
25T
40 sq. m.
Station
11
16 sq. m.
ALLOWANCE
ENGINE
General Assy
Station
5.5 m, 1/2 T
23 sq. m.
NE
83 sq. m.
DRI
LL
ALLOWANCE
MA
CHI
NE
Station
10
16 sq. m.
ALLOWANCE
ENGINE
2.5m.
CONROD
CONR
MACHINE
23 sq. m.
FIP
Allowance
Tester
CONROD
ALLIGNMENT TOOL
FIP Allowance
Testbench
WIP Crankshaft
& Cam Shaft Polsh
POLISH
MACHINE
CrankShaft Grinding
CRANKSHAFT GRINDING 2
2
50 sq. m.
Block, Diff House
Fabrication
Room
2
Station
9
16 sq. m.
ALLOWANCE
ENGINE
WIP SUB ASSY
94 sq. m.
SPRAY
WASH
WATER
ALLOWAN
SWE80
0 CE
2T, 5.5 m
OHC 5 T
CrankShaft
Grinding
CRANKSHAFT GRINDING
1
1
41 sq. m.
VERTICAL BORING
A
R
C
W
ALLOWAN
EL
CE
DI
N
G
1
ALLOWANCE
ENGINE
HYD
14 sq. m.
2 T, 5.5 m
M. FLUX
WIP Machining
ARC
Station
8 m.
16 sq.
ALLOWANCE
ENGINE
24 sq. m.
2T, 5.5 m
WEL
ALLOWANCE
DING
112 sq. m.
Station
7 m.
16 sq.
Station
6 m.
16 sq.
ALLOWANCE
ENGINE
HYD
MAGNAFLUX
WIP
AXLE
TUBE
WIP
Fab
18 sq. m.
Roller
Conv.
2.4m.
WIP
Short Block
72 sq. m.
MARKING
AREA
36 sq. m.
Station
5 m.
16 sq.
ALLOWANCE
ENGINE
6.1m.
2 T, 5.5 m
2.2m.
Station
ALLOWANCE
ENGINE
4 m.
16 sq.
PRESS
ALLOWAN
STAND
CE
Send
Out
House
15 Fab
sq. m.
ALLOWANCE
ENGINE
PRESS
ALLOWAN
STAND
CE
Receive
Out
House
17 Fab
sq. m.
Station
3 m.
16 sq.
Station
2 m.
16 sq.
ALLOWANCE
ENGINE
1/2 T, 5.5 m
3.0m.
2T, 5.5 m
OFFICE
Station
ALLOWANCE
16ENGINE
sq.
1 m.
5 m, ½ T
Piston &
ConRod
Preparation
9 sq. m.
C/ Shaft
Cleaning
Measure
9 sq. m.
Short Block 1
Install
Bushing &
ALLOWANCE
ENGINE
Plug
15 sq. m.
Block
Liner & Oring
Preparation
Liner
Assembly
Area
Wash.
9 sq. m.
9 sq. m.
2 sq. m.
Short Block 2
Install
Liner
ALLOWANCE
ENGINE
15 sq. m.
Preparation
Line
208 sq. m.
5 m, ½ T
Short Block 3
C/ENGINE
Shaft
ALLOWANCE
15 sq. m.
2T, 5.5 m
Short Block 4
Piston &
ALLOWANCE
ENGINE
ConRod
15 sq. m.
3.0m.
Up
RFU
Short Block
91 sq. m.
OHC 5T
2 T, 5.5 m
LATHE
ALLOWANCE
MACHINE 5
36 sq. m.
OFFICE
ROUGHNES
S TESTER
MACHINING/FAB.
& Lab
(office Lt 2
Lab Lt 1)
Parts Prepare
& Tools
Area
15 sq. m.
Short Block 6
Short Block 5
Short Block 7
Fly/W Housing, Gear Case
Short Block 8
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
Oil
Pump &
Timing
Gear
FIP Drive, Cam Shaft
Front Cover
Strainer
Assy & Measure
Oil Pan
15 sq. m.
15 sq. m.
15 sq. m.
15 sq. m.
MILLING & LATHE
LATHE
ALLOWANCE
MACHINE
MACHINE 4
MILLING
ALLOWANCE
MACHINE 3
CMM
PORTAB
LE
Parts Prepare
& Tools
Area
15 sq. m.
½ T, 5 m
54 sq. m.
Parts Prepare
& Tools
Area
15 sq. m.
½ T, 5 m
15 sq. m.
½ T, 5 m
MACHINE 3
2 T, 5.5 m
Oil Pump &
Strainer
Preparation
LATHE
189 sq. m.
ALLOWANCE
12 sq. m.
LATHE
ALLOWANCE
MACHINE 1
12 sq. m.
MILLIN
G
ALLOWANCE
MACHI
NE 2
WIP
Fab
2.5m.
30 sq. m.
MILLING
ALLOWANCE
MACHIN
E1
ENGINE
PRE
WASH
13 sq. m.
OIL
TRAP
GARDEN
8 sq. m.
TOILET
11 sq. m.
GARDEN
8 sq. m.
66.0m.
78 sq. m.
40 sq. m.
ALLOWANCE
ENGINE
60.0m.
24 sq. m.
ARM
INTAKE MANIFOLD
WATER PUMP
PUSH ROD
HEATER
CORROSION RESISTOR
ST. MOTOR
AFTER COOLER
ASSEMBLING
ASSEMBLING
ASSEMBLING
30 sq. m.
30 sq. m.
36 sq. m.
½ T, 5.5 m
24 sq. m.
Startin
g
ALLOWANCE
motor
testbe
ROCKER
nch
CROSS HEAD
PULLEY GROUP
DAMPER
ASSEMBLING
42 sq. m.
CYLINDER HEAD
& EXHAUST MANIFOLD
ASSEMBLING
MAINTENANCE
ROOM
DYNO TEST
PREPARATION
ALLOWANCE
ENGINE
ALLOWANCE
ENGINE
77 sq. m.
½ T, 5.5 m
OIL PUMP &
OIL COOLER &
PISTON
CAM FOLLOWER
COOLING NOZZLE
ASSEMBLING
ASSEMBLING
½ T, 5.5 m
66 sq. m.
½ T, 5.5 m
RFU
OIL PAN
F/W HOUSING & FLYWHEEL
GEAR CASE & COVER
91 sq. m.
40 sq. m.
Compressor
Room
40 sq. m.
6.0m.
WAREHOUSE
Compressor
Tanks
42 sq. m.
OHC 10 T
OHC 5 T
WAREHOUSE
Masking &
Preparation
Before
Painting
ASSY’ PAINTING
ROOM
3.2m.
519 sq. m.
3.3m.
Receiving
Parts