FLOW, SPACE, AND ACTIVITY RELATIONSHIP

  Flow, Space, and Activity Relationship

• In determining the requirements of a facility, three important considerations are:
• – Flow
• Depends on lot sizes, unit load sizes, material handling equipment and strategies, layout arrangement, and building configuration
• – Space
• Is a function of lot sizes, storage system, production equipment type and size, layout arrangement, building configuration, housekeeping and organization policies, material handling

  Mata Kuliah: Tata Letak Fasilitas (TKI 4215)

  equipment, and office, cafetaria, and resttoom design

• – Activity relatioships

FLOW, SPACE, AND ACTIVITY

• Are defined by material or personal flow, environmental considerations, organizational structure, continous improvement methodology (teamwork activities), control issues, and process

  RELATIONSHIP

  requirements

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id Data requirement for layout decisions

• Frequency of flow of material / some other measure of interaction between departments
• Shape and size of departments
• Floor space available
• Location restrictions for departments, if any

DEPARTMENTAL PLANNING

• Adjacency requirements between pairs of departments, if any

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id

  S h ip p in g D e p a r tm e n t R e c e iv in g D e p a r tm e n t Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id

  www.aeunike.lecture.ub.ac.id Product layout www.aeunike.lecture.ub.ac.id

  A

  Product B Department

  P P P

  Product C Department Product A Department

  L L L L L M M M D D D D G G G G A A

  Product Layouts

  Five types of layout

  Types of Departments/Layouts Volume

  Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id

  Product Layout Fixed Location Layout Group Technology Layout Process Layout

  Department Product Family Department

  Product Department Fixed Materials Location Department Process

  Low Low Medium High Variety

  High Medium

• Product layout
• Process layout
• Fixed-position layout
• Group-technology layout
• Hybrid layout

Process layout

  TM TM TM TM DM DM DM

  P P

  VMM

  L L L L L L L L L L M M M M D D D D D D D D G G G G G G A A A

VMM BM BM

  Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department

  Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id

  Flow of Materials in Process Layouts

  L L L L L L L L L L M M M M D D D D D D D D G G G G G G A A A Product Family (Cellular) Layout A Manufacturing Cell

  www.aeunike.lecture.ub.ac.id The Process Layout

  P P

  Source: Russell & Taylor, 2007 www.aeunike.lecture.ub.ac.id

  Group technology layout

  TM TM TM TM DM DM DM

  VMM

  VMM BM BM

  www.aeunike.lecture.ub.ac.id

  Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department

  G

  HM

  G G D D D ll

  e

  VM

  L L c

  in

  D M G Paths of three D th Worker 3 L workers moving

  wi P within cell

  VM

  L

  t n

  G M

  e

  D L L Material

  m e Rotational movement v P o Parts

  L L m

   Cell M D t r

  Key: Worker 2

  a p G Rectangular f

  L G S = Saw

   o Parts

  M

  n

  L L = Lathe L

   Cell o

  A

  Special ti

  HM = Horizontal milling machine

  c

  A Department e Final

  VM = Vertical milling machine

  inspection ir

  G = Grinder

  D Receiving and Finished Shipping part Worker 1 S

  Out In

  Source: John S. Usher class notes Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id

  Project (Fixed-Position) Layout Hybrid layout

  G G D D D L G L

TM TM

  S S

  G

  to to r r a ge a ge

  L DM TM TM A L A M P

  Receiving and Shipping Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id

  General Characteristics Hybrid Layouts

  Product Characteristic Product Process Project Family • Combination of the layouts discussed.

  Throughput Time Low High Low Medium

• A combination of group layout in manufacturing cells, product layout in assembly area, and process layout in the Work in process Low High Low Medium general machining and finishing section is used.

  Skill Level Choice High Med-High Mixed Product Flexibility Low High Med-High High

  TM DM TM TM Demand Flexibility Medium High Medium Medium

  Mach Utilization High Med-Low Medium-High Medium

  TM TM Worker Utilization High High High Medium BM

  Reliability Can be High High Medium low Unit production Low High Low High cost

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id Exercise Automated Manufacturing Cell

• – What Type of Layout?
• Ford Louisville Assembly Plant ___________
• Suburban Hospital ___________
• Louisville International Airport ___________
• KFC Restaurant ___________
• Boeing Aircraft ___________

  Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id

  Flexible Manufacturing Systems  Automated machining operations, tool changers  Automated material handling, computer control  Designed around size of parts processed & average processing time for parts  Can process wide variety of items quickly  Very few large systems exist

DIAGRAM ALIR (FLOW DIAGRAM)

MESIN FRAIS MESIN BUBUT MESIN BOR MESIN BOR

• Progressive layout – all parts same route
• Closed loop – larger variety, alternative routes
• Ladder layout – two machines work on same part
• Open field layout – most complex

  www.aeunike.lecture.ub.ac.id Flow diagram www.aeunike.lecture.ub.ac.id

  ^{MEJA PE N E R IM A A N} _{P E} ^{N Y IM P A N A N A L A T} _{M E J A P E R A K IT A N} ^{Peluncur Bahan} _{Peluncur Bahan} PEMANGGANG P A

  IN T

  ING ^{P E N GE M A S A N Peluncur Bahan Peluncur Bahan Peluncur Bahan Peluncur Bahan Peluncur Bahan} _{Peluncur Bahan} ^{Peluncur Bahan 1 1 2 2 1 3 MEJA 3 3 2 5 4 6 3 6 5 7 6 8 4 9 5} ₁ ¹ ₇ ^{1 2} _{8 1 3 6} ^{1 4 9 1 5 7 10 1 6 1 7 11 1 8 8}

  18 _{12 2 13 P E N G IR IM A N} FINISHING ASSEMBLING G U D A N G

  www.aeunike.lecture.ub.ac.id Flow pattern at 800-acre Nissan plant in Smyrna, TN (1989) www.aeunike.lecture.ub.ac.id

• Proses yang berlangsung singkat
• Proses produksinya relatif sederhana • Item tunggal/sedikit, jumlah produksi yang besar.
• Pola aliran bahan ini akan memberikan : – Jarak perpindahan yang pendek antar proses.
• – Proses berlangsung lurus sesuai urutan mesin
• Jarak perpindahan bahan total akan kecil

  www.aeunike.lecture.ub.ac.id Flow Within Departments:

  (a). End-to-end; (b). Back-to-back; (c). Front-to-front; (d). Circular; (e). Odd angle

  Flow Between Departments: Straight Line atau pola aliran lurus ( I Flow)

  O-1 O-2 O-3 O-4 O-5

  Flow Between Departments: Serpentine atau zig-zag (S Flow)

O-1 O-2 O-3 O-4 O-5 O-6

  (A)

  O-1 O-2 O-3 O-4 O-5 O-6 O-1 O-2 O-4 O-3 O-5 O-6

  (B) Pola aliran seperti huruf “S” diatas sangat baik diterapkan bilamana aliran proses produksi lebih panjang dibandingkan dengan panjang area yang tersedia. Untuk itu aliran bahan dibelokkan untuk mengurangi panjangnya garis aliran yang ada.

  Flow Between Departments: Pola aliran menyerupai huruf “U” (U Flow)

  Pola aliran ini dipakai bilamana dikehendaki akhir dari proses produksi akan berada pada lokasi yang sama dengan awal proses produksi. Hal ini meningkatkan pemanfaatan fasilitas transportasi dan mudah untuk mengawasi keluar masuknya material dan produk jadi. Aliran perpindahan bahan relatif panjang . Flow Between Departments: Flow Between Departments:

  Circular ODD angle

  (O Flow)

  O-3

  O-2

  O-2 O-4

O-3 O-1 O-6

  O-1 O-5

  O-4

  O-6

  O-5 Pola aliran circular ini sangat baik diterapkan pada proses yang mengkehendaki pengembalian material atau produk jadi pada titik awal • Tujuannya adalah untuk memperoleh garis aliran produk melewati suatu kelompok kerja dari area yang saling berkaitan. produksi. Pola ini juga dapat diterapkan pada proses yang menempatkan • Proses perpindahan bahan (Material handling) secara mekanik. proses penerimaan bahan/material dan pengiriman barang jadi pada area

• Terbatasnya ruang dan dikehendaki adanya pola aliran yang tetap yang sama.

  POLA ALIRAN MENURUT KELUAR-MASUK BAHAN POLA ALIRAN MENURUT KELUAR-MASUK BAHAN ON THE SAME SIDE BUT AT OPPOSITE ENDS ON THE SAME SIDE BUT AT OPPOSITE ENDS AT THE SAME LOCATION AT THE SAME LOCATION ON OPPOSITE SIDES ON OPPOSITE SIDES ON ADJACENT SLIDES ON ADJACENT SLIDES

  A B E D C H F G

  UNINTERRUPTED FLOW PATHS

  A F E H C G B D

PROSES PERAKITAN (ASSEMBLY)

  INTERRUPTED FLOW PATHS

  MACAM POLA ALIRAN YANG BERSILANGAN POLA ALIRAN BAHAN UNTUK

  Pada pola aliran ini main assembly line akan disupplai dari sejumlah sub-assembly atau part line. Sub-assembly berada pada sisi yang sama.

  Pola aliran bahan untuk proses perakitan: Combination Assembly Line Patern Pola aliran bahan untuk proses perakitan: Tree Assembly Line / Spine Flow Patern

  Sub-assembly line akan berada pada kedua sisi dari aliran main assembly. Biasanya pada penerapan pola aliran ini, main assembly akan berada ditengah bagian pabrik. Pola aliran bahan untuk proses perakitan: Pola aliran bahan untuk proses perakitan: Dendretic Assembly Line Patern Overhead Assembly Line Patern

  2nd Floor 1st Floor Pola ini akan lebih tidak teratur dibanding dengan pola aliran sebelumnya.

  Pada pola aliran ini, setiap bagian berlangsung operasi sepanjang lintasan Pola aliran ini merupakan model pola aliran untuk produksi, menuju proses produksi yang lengkap untuk proses assembling. lantai produksi yang lebih dari satu lantai.

  Flow planning hierarchy

FLOW PLANNING

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id Flow Measurement String Diagram merupakan alat untuk menggambarkan aliran bahan/material dalam layout, dengan menggunakan tali, benang, kawat, dan sebagainya.

  A. STRING DIAGRAM O

  Tahapan pembuatan :

• Tusukkan paku, baut atau jarum pentul pada fasilitas-

  fasilitas dalam layout (pada titik proses dimulai atau berhenti)

• Hubungkan paku atau jarum yang telah dipasang sesuai dengan keterkaitan proses atau alur proses.
• Gunakan penghubung antar paku/titik menggunakan

  benang, karet, tali yang berwarna-warni

  B. FROM TO CHART O

6 W/H MATERIAL

  2

  7 W/H FINISH GOOD

  5

  3

  9 10 11

  12

  13

  4 PENGOLAHAN LIMBAH Kemungkinan terjadinya kemacetan aliran

  1

  Dikenal juga sebagai Travel Chart O

  Suatu teknik konvensional yang umum digunakan untuk perencanaan tata letak pabrik dan pemindahan bahan dalam suatu proses produksi.

  O Sangat berguna dalam menganalisa aliran bahan pada proses dengan banyak item yang mengalir melalui suatu area.

  O Teknik ini akan menunjukkan total berat beban yang harus dipindahkan, jarak perpindahan dan volume perpindahan

  8

LANGKAH PENYELESAIAN

DIMENSI DEPARTEMEN

  PRODUK

  VOLUME OF HANDLING % VOLUME

  OF HANDLING ALUR PROSES P1 2000 Kg

  20 A-B-C-D-E-F-G-H-I P2 2000 Kg

  20 A-C-D-F-G-I P3 2500 Kg

  25 A-D-B-E-H-F-I P4 2000 Kg

  20 A-C-D-B-E-G-I P5 500 Kg

  5 A-E-F-G-H-I P6 500 Kg

  5 A-D-C-B-F-G-H_I P7 500 Kg

  5 A-C-D-H-D-G-I

  O Kumpulkan data “Volume of Handling”, luas area/departemen & alur proses produksi tiap produk

  DEPARTEMEN DIMENSI (meter )

  A 10 x 10 B 5 x 5 C 8 x 10 D 10 x 5 E 25 x 10 F 5 x 5 G 5 x 10 H 8 x 8

  I 16 x 16

KONDISI AWAL

  A B C D E F G H

  20

  65 5 100

  E

  5

  45

  20

  70 F

  5

  20

  25

  25

  75 G

  5

  50

  I TO A B

  75 H

  5

  25

  30

  60 J

  25

  45 30 100 100 70 70 100

  70

  75

  75 60 620

  Buatlah from to chart berdasarkan % volume handling (jarak untuk sementara dianggap sama)

  O

  30

  70 D

  5

  20

  20

  5 25+2

  C

  20+20+

  5

  20

  5 D 25+5 20+20+20+5

  5 E 5 25+20

  20 F

  5

  20 20+

  5

  25 G

  5 20 20+20+5+5

  H

  5 25 20+5+5

  I

  25 20+20+5 20+5+

  dari A ke B Sebesar 20

  FROM

  A B C D E F G H J TO A B

  20

  5

  45

  70 C

  45

  FROM

5 Perpindahan P1

  Volume Aliran Dari Jarak BACK TRACKING Diagonal FORWARD BACKWARD

• Pada From to Chart diketahui adanya Back

  Jarak dari Koefisien Jarak dari

  Tracking sebesar 15% dari total aliran bahan

  diagonal Moment Jarak Moment diagonal (ditandai dengan warna merah).

  (20+20+65+20+25+50+30+

  Semakin kecil back tracking akan semakin baik = 260 1 =10

• 30) (260 x 1) (10 x 1) (5+5)

  = 260 =10

• Sehingga diperlukan evaluasi aliran proses yang

  (45+20+20+45) (130 x 2) (70 x 2) (45+25) =130 =70 mengalami back tracking, dalam kasus diatas

  = 260

  2 =140 adalah pada produk P3 dengan aliran awal A-D-

  (30+45+5+25+25) (130 x 3) =130

  = 390

3 B-E-H-F-I

  Kemudian dilakukan perubahan terhadap aliran =15

• (5+5+5) (15 x 4) (5 x 4)

  4

  5

  = 60 =20

  P3 menjadi A-B-D-E-F-H-I

  Besarnya perubahan terhadap aliran P3 dapat

• 5

  6 dilihat pada tahap berikut ini.

  970 1140 170

  85% 15% Kondisi setelah perubahan aliran

KONDISI PERBAIKAN

  A-B-D-E-F-H-I FROM FROM TO A B C D E F G H

  I TO A B C D E F G H

  I A A

  B 20+25

  5

  20 B

  45

  5

  20 20+20+

  C

  45

  20

  5

  20

  5 20+20+20

  5 C

  D

  5

  25

  65

  5

  5 25 +5

  5 D 20+2

  E

  5

  20

  45

  5

  20

  5 E 20+5+2

  F

  5

  20

  50 F

  5

  20

  5 20+20+5+

  G

  5

  20

  50 G

  5

  20

5 H

  5

  25

  30

  5 25 20+5+5

  H

  20+20+ 20+5+5+2

  I

  45

  55 I

  5

  5

  Volume Aliran Dari Jarak Diagonal FRWD Koefisien Jarak BCWD Jarak dari diagonal Moment Jarak dari diagonal Moment 360 360

  E 3-10% O

  Kode Derajat Hubungan Antar Fasilitas Value A E

  I O U

  X Closeness Line code Numerical weights Absolutely necessary Especially important Important Ordinary closeness OK Unimportant Undesirable

  16

  8

  4

  2

  Percentages of A, E, I, O, U and X ratings O

  A 2-5% O

  I 5-15% O

  3. Tentukan nilai hubungan antar fasilitas

  O 10-25% O

  U 25-60% O

  X depends O

  Color coding relationships O

  A Red O

  E Orange or Yellow O

  I Green O

  O Blue O

  U Uncolored O

  X Brown

  4. Plot hasil perumusan nilai hubungan dalam ARC Teknik kualitatif yang sederhana dalam merencanakan tata letak fasilitas atau mesin. Berdasarkan derajat hubungan aktivitas dari masing-masing fasilitas atau mesin tersebut.

  2. Definisikan kriteria hubungan antar fasilitas kerja

  1

  60

  10

  10 180 360

  2

  40

  20

  30

  90

  3

  15

  4

  1. Identifikasi semua fasilitas kerja / departemen / mesin

  20

  5

  5

  6

  7

  8

  870 940

  70 93% 7%

  C. ACTIVITY RELATIONSHIP CHART O

  Prosedur pembuatan Activity Relationship Chart (ARC) sebagai berikut :

80 O

  I X O FASILITAS A FASILITAS B FASILITAS C

  6 Keterkaitan urutan proses kerja

  2

  1

  1

  3

  Alasan kedekatan hubungan ACTIVITY RELATION CHART Contoh Alasan Kedekatan Hubungan KODE ALASAN DESKRIPSI ALASAN KEDEKATAN

  1 Penggunaan data hasil proses secara besamaan

  2 Penggunaan man power sharing

  3 Penggunaan space area sharing

  4 Tingginya tingkat hubungan personil

  5 Keterkaitan pemakaian worksheet

2 Derajat hubungan

  7 Kesamaan proses kerja

  Punch Press 2 (15 x 15) Vertical Turret Lathe (10 x 10) Lathe (10 x 15) Drill 1(10 x 10) Mill (20 x 20) Punch Press (15 x 15) Centerless Grinder (15 x 15) Shaper (10 x 20) Planer (10 x 20) Drill 2(10 x 10) Mill 2(15 x 20)

  9 ^{3 4 2 1 3 7 1 5 4 2 7 4 6 5 8 1 2 4 6 2 1 1 5 3 1 4 9 2 2 3 4 4 8 2 7 7 2 2 4 3 5 7 4 6 8} ₉ ^{3 6} _{9 1} ^{7 3 6} _{5 2 9 5 1 5 3 3} ^{5 5 5 7} ACTIVITY RELATIONSHIP CHART SPACE REQUIREMENT www.aeunike.lecture.ub.ac.id

  8

  7

  6

  5

  4

  3

  2

  1

  12

  11

  10

  I CNC Machine (10 x 25)

  8 Penggunaan jig and tools secara bersama

  I U O O U U U U E U

  X A U A U

  X O O U E

  I U O U U O U

  I A U A

  I E O

  3

  I E

  X A O A O E O

  I U O O A A E U O E U E

  I E E U O O U

  A

  9 Ketidaknyamanan ketika berdekatan

  I A Space Requirements Space Requirements

• In manufacturing and office environments, space
• The most difficult determination in facilities

  requirements should be determined first for individual planning workstations; next, departments, etc.

• The design year: 5-10 years • Modern manufacturing approaches can reduce space requirements.
• Uncertainty –due to impact of technology,
• – Products are delivered to the points of use in

  Changing product mix, changing demand smaller lot and unit load size levels, changing organization designs for the

• – Decentralised storage areas

  future

• – Less inventories (using a pulled system)
• Needs a systematic approach: “From the
• – Manufacturing cells

  ground up”

• – Companies are downsizing

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id Space Requirements Space Requirements

• Workstation Specification (space for equipment, materials, and personnel)
• Department Specifica
• Equipment Space consists of space for
• Aisle Arrangement
• – the equipment; machine travel;machine maintenance;
• – plant services
• Visual Management and Space
• Materials Space consists of space for

  Requirement

• – Receiving and storing materials; In-process materials;
• – Storing and shipping materials; Storing and shipping waste and scrap; Tools, fixtures, jig, dies, and maintenance materials
• Personnel area consists of space for
• – The operator; Material handling; Operator ingress and egress.

  www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id Space Requirements Space Requirements Simple rules of thumb are used to determine the extra space that is required (Heragu, 1997)

  

  3

• – 4 feet are added to the length and width of each machine or workstation The additional space is calculated as a percentage  of the actual area occupied by a workstation, typically 200% to 300% Calculate the space required for the workstation,  auxiliary equipment, operator space, incoming material and work in process space, and other additional space (e.g., load and unload acces, material handling carrier clearance) and add the separate quantities to determine the total space required (the preffered method of determining

  extra space) www.aeunike.lecture.ub.ac.id

  Workstation Aisle Allowance www.aeunike.lecture.ub.ac.id www.aeunike.lecture.ub.ac.id

• Keterangan gambar:

  10. Manufacturing instructions and technical procedures area

  19. Improvement activities

  E. Progress status

  18. Objectives, result, and difference

  D. Performance measurement

  17. Record of problems

  16. Statistical process control

  15. Monitoring signals for machines

  14. Identification of inventories and work-in process

  13. Maintenance schedule

  12. Production schedule

  11. Computer terminal

  C. Visual production, maintenance, inventory, and quality control

  B. Visual documentation

  www.aeunike.lecture.ub.ac.id Departmental Service www.aeunike.lecture.ub.ac.id

  9. Housekeeping tools

  8. Information and instructions

  7. Communication and rest area

  6. Technical area

  5. Markings of tools, racks, fixtures

  4. Markings on the floor

  3. Identification of the team

  2. Identification of activities, resources, and products

  1. Identification of the department

  A. Identification, housekeeping, and organization

  Visual Management Visual Management

  Aisle Widths www.aeunike.lecture.ub.ac.id

  20. Company project and mission statement www.aeunike.lecture.ub.ac.id References • Heragu, S. (2008). Facilities Design (3rd Ed.).

  CRC Press.

• Tompkins, White, Bozer and Tanchoco.

  (2010). Facilities Planning (4th Ed.). New York: Wiley.

• Wignjosoebroto, S. (1996). Tata Letak

  Pabrik dan Pemindahan Bahan. Surabaya: Guna Widya.