Mata Kuliah: Tata Letak Fasilitas (TKI 4215) FLOW, SPACE ... · String Diagram merupakan alat untuk...

FLOW, SPACE, AND ACTIVITY

RELATIONSHIP

Mata Kuliah: Tata Letak Fasilitas (TKI 4215)

www.aeunike.lecture.ub.ac.id

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 equipment, and office, cafetaria, and resttoom design

– Activity relatioships • Are defined by material or personal flow, environmental

considerations, organizational structure, continous improvement methodology (teamwork activities), control issues, and process requirements


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

• Adjacency requirements between pairs of departments, if any


FLOW PATTERN


Flow pattern at 800-acre Nissan plant in

Smyrna, TN (1989)



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)

• 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

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


Serpentine atau zig-zag

(S Flow)

(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.


Pola aliran menyerupai huruf “U”

(U Flow)

O-1 O-2 O-3

O-4O-5O-6

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 .

O-1

O-2

O-3

O-4

O-5

O-6

Pola aliran circular ini sangat baik diterapkan pada proses yang mengkehendaki pengembalian material atau produk jadi pada titik awal produksi. Pola ini juga dapat diterapkan pada proses yang menempatkan proses penerimaan bahan/material dan pengiriman barang jadi pada area yang sama.


Circular

(O Flow)

O-1

O-2

O-3

O-4

O-5

O-6

• Tujuannya adalah untuk memperoleh garis aliran produk melewati suatu kelompok kerja dari area yang saling berkaitan.

• Proses perpindahan bahan (Material handling) secara mekanik. • Terbatasnya ruang dan dikehendaki adanya pola aliran yang tetap


ODD angle

AT THE SAME LOCATION

ON ADJACENT SLIDES

AT THE SAME LOCATION

ON ADJACENT SLIDES

POLA ALIRAN MENURUT KELUAR-MASUK BAHAN

ON THE SAME SIDE BUT AT OPPOSITE ENDS ON THE SAME SIDE BUT AT OPPOSITE ENDS

ON OPPOSITE SIDES ON OPPOSITE SIDES

POLA ALIRAN MENURUT KELUAR-MASUK BAHAN

A B

E

DC

HF G

UNINTERRUPTED FLOW PATHS

A F

E

HC

GB D

INTERRUPTED FLOW PATHS

MACAM POLA ALIRAN YANG BERSILANGAN

POLA ALIRAN BAHAN UNTUK

PROSES PERAKITAN (ASSEMBLY)

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


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 ini akan lebih tidak teratur dibanding dengan pola aliran sebelumnya. Pada pola aliran ini, setiap bagian berlangsung operasi sepanjang lintasan produksi, menuju proses produksi yang lengkap untuk proses assembling.


Dendretic Assembly Line Patern


Overhead Assembly Line Patern

2nd Floor

1st Floor

Pola aliran ini merupakan model pola aliran untuk lantai produksi yang lebih dari satu lantai.

Types of Departments/Layouts Volume

High

Medium

Low

Low Medium High Variety

Product

Department

Fixed Materials

Location

Department

Process

Department

Product

Family

Department

Product

Layout

Fixed Location

Layout

Group Technology

Layout

Process

Layout

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

Five types of layout

• Product layout

• Process layout

• Fixed-position layout

• Group-technology layout

• Hybrid layout


Product layout


Product Layouts

L

L

L L

L M

M

M

D D

D

D G

G

G

G A

A

Product C Department

Product A Department

P

P

P

Product B Department

A

Sh

ipp

ing

De

pa

rtme

nt

Re

ceiv

ing

De

pa

rtme

nt


Process layout

TM

TM TM

TM

DM

DM

DM

VMM VMM BM BM


The Process Layout

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 Receiving and Shipping Assembly

Painting Department

Lathe Department Milling

Department Drilling Department

Grinding Department

P

P


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 Receiving and Shipping Assembly

Painting Department

Lathe Department Milling

Department Drilling Department

Grinding Department

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


Product Family (Cellular) Layout

L

L

L

L

L

L

L

L

L M

M

M

M

D D

D D

D

D

D

G

G

G G

G

G

A A

Receiving and Shipping

Special Department

Rotational Parts Cell

P

P

Rectangular Parts Cell


A Manufacturing Cell

Key: S = Saw L = Lathe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder

Paths of three workers moving within cell Material movement

In Out Worker 1

Worker 2

Worker 3

Dir

ect

ion

of

pa

rt m

ov

em

en

t w

ith

in c

ell

S

L

HM

VM

G

VM

L

Final inspection

Finished part


Project (Fixed-Position) Layout

L

L

L

L

M

D D D

G

G G

G

A

A

Receiving and Shipping

P

Sto

rag

e

Sto

rag

e


Hybrid layout

TM

TM TM

TM

DM

VMM BM


Hybrid Layouts

• Combination of the layouts discussed. • A combination of group layout in manufacturing cells,

product layout in assembly area, and process layout in the general machining and finishing section is used.

TM

TM TM

TM TM DM

BM


General Characteristics

Characteristic Product Process Product

Family Project

Throughput Time Low High Low Medium

Work in process Low High Low Medium

Skill Level Choice High Med-High Mixed

Product Flexibility Low High Med-High High

Demand Flexibility Medium High Medium Medium

Mach Utilization High Med-Low Medium-High Medium

Worker Utilization High High High Medium

Reliability Can be

low

High High Medium

Unit production

cost

Low High Low High


Exercise – What Type of Layout?

• Ford Louisville Assembly Plant ___________

• Suburban Hospital ___________

• Louisville International Airport ___________

• KFC Restaurant ___________

• Boeing Aircraft ___________


Automated Manufacturing Cell


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

• 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


Flow diagram


MESIN FRAIS MESIN BUBUT

MESIN BORMESIN BOR

MEJA

PE

NE

RIM

AA

NP

EN

YIM

PA

NA

N

AL

AT

ME

JA

PE

RA

KIT

AN

Peluncur

Bahan

Peluncur

Bahan

PEMANGGANG

PA

INT

ING

PE

NG

EM

AS

AN

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

65

7

6

8

4

9

5

11

7

12

8

13

6

14

9

15

7

10

16 1

7

11

18

8

18

12

20

13

PE

NG

IRIM

AN

FINISHINGASSEMBLING

GU

DA

NG

DIAGRAM ALIR (FLOW DIAGRAM)

FLOW PLANNING


Flow planning hierarchy


Flow Measurement

String Diagram merupakan alat untuk menggambarkan aliran bahan/material dalam layout,

dengan menggunakan tali, benang, kawat, dan sebagainya.

A. STRING DIAGRAM

OTahapan 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

1

3

2

7

W/H

FINISH

GOOD

5

6

W/H MATERIAL8 9

10 11

12

13

4

PENGOLAHAN

LIMBAH

Kemungkinan terjadinya kemacetan aliran

B. FROM TO CHART

O 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

LANGKAH PENYELESAIAN

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

DIMENSI DEPARTEMEN

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

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

FROM

A B C D E F G H I TO

A

B 20 5

25+20

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+5

Perpindahan P1 dari A ke B Sebesar 20

FROM

A B C D E F G H J TO

A 0

B 20 5 45 70

C 45 20 5 70

D 30 65 5 100

E 5 45 20 70

F 5 20 25 25 75

G 5 20 50 75

H 5 25 30 60

J 25 45 30 100

100 70 70 100 70 75 75 60 0 620

KONDISI AWAL

Volume Aliran Dari Jarak Diagonal

FORWARD

Koefisien

Jarak

BACKWARD

Jarak dari

diagonal Moment Moment

Jarak dari

diagonal

(20+20+65+20+25+50+30+

30)

= 260 (260 x 1)

= 260 1

(10 x 1)

=10 (5+5)

=10

(45+20+20+45)

=130 (130 x 2)

= 260 2

(70 x 2)

=140 (45+25)

=70

(30+45+5+25+25)

=130 (130 x 3)

= 390 3 0 0

(5+5+5)

=15 (15 x 4)

= 60 4

(5 x 4)

=20 5

0 0 5 0 0

0 0 6 0 0

970 1140 170

85% 15%

BACK TRACKING

• Pada From to Chart diketahui adanya Back Tracking sebesar 15% dari total aliran bahan (ditandai dengan warna merah).

• Semakin kecil back tracking akan semakin baik • Sehingga diperlukan evaluasi aliran proses yang

mengalami back tracking, dalam kasus diatas adalah pada produk P3 dengan aliran awal A-D-B-E-H-F-I

• Kemudian dilakukan perubahan terhadap aliran P3 menjadi A-B-D-E-F-H-I

• Besarnya perubahan terhadap aliran P3 dapat dilihat pada tahap berikut ini.

FROM


A

B 20+25 5 20

C 20+20+

5 20 5

D 5 25

20+20+20+5 5

E 5 20 20+2

5

F 5 20

20+5+25

G 5 20

20+20+5+5

H 5 25 20+5+5

I 20+20+

5

20+5+5+25

Kondisi setelah perubahan aliran A-B-D-E-F-H-I

FROM


A

B 45 5 20

C 45 20 5

D 5 25 65 5

E 5 20 45

F 5 20 50

G 5 20 50

H 5 25 30

I 45 55

KONDISI PERBAIKAN

Volume Aliran Dari Jarak Diagonal

FRWD

Koefisien

Jarak

BCWD

Jarak dari

diagonal Moment

Jarak dari

diagonal Moment

360 360 1 10 10

180 360 2 40 20

30 90 3 0 0

15 60 4 20 5

0 0 5 0 0

0 0 6 0 0

0 0 7 0 0

0 0 8 0 0

870 940 70

93% 7%

C. ACTIVITY RELATIONSHIP CHART

O Prosedur pembuatan Activity Relationship Chart (ARC) sebagai berikut :

1. Identifikasi semua fasilitas kerja / departemen / mesin 2. Definisikan kriteria hubungan antar fasilitas kerja 3. Tentukan nilai hubungan antar fasilitas 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.

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

0

80

O Percentages of A, E, I, O, U and X ratings O A 2-5% O E 3-10% O I 5-15% O 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

I

X

O

FASILITAS A

FASILITAS B

FASILITAS C

1

2

3

1

3

2

Derajat hubungan

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

6 Keterkaitan urutan proses kerja

7 Kesamaan proses kerja

8 Penggunaan jig and tools secara bersama

9 Ketidaknyamanan ketika berdekatan

A

I

E

E

U

O

O

U

I

U

O

O

A

A

E

U

O

E

U

E

X

A

O

A

O

E

O

I

E

I

A

I

E

O

I

A

U

A

I

U

O

U

U

O

U

X

O

O

U

E

X

A

U

A

U

I

U

O

O

U

U

U

U

E

UI

CNC Machine (10 x 25)

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)

10

11

12

1

2

3

4

5

6

7

8

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

14

9

2

2

3

44

8

2

7

7

2

2

4

3

5

7 4

6 8

9

36

9

1

7

3

6

5

2

9

5

1

5

3

3

5

5

5

7

ACTIVITY RELATIONSHIP

CHART

SPACE REQUIREMENT


Space Requirements

• The most difficult determination in facilities planning

• The design year: 5-10 years

• Uncertainty –due to impact of technology, Changing product mix, changing demand levels, changing organization designs for the future

• Needs a systematic approach: “From the ground up”


• In manufacturing and office environments, space requirements should be determined first for individual workstations; next, departments, etc.

• Modern manufacturing approaches can reduce space requirements.

– Products are delivered to the points of use in smaller lot and unit load size

– Decentralised storage areas

– Less inventories (using a pulled system)

– Manufacturing cells

– Companies are downsizing


Space Requirements

Space Requirements

• Workstation Specification (space for equipment, materials, and personnel)

• Equipment Space consists of space for

– the equipment; machine travel;machine maintenance; – plant services

• Materials Space consists of space for

– 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.


Space Requirements

• Department Specification

• Aisle Arrangement

• Visual Management and Space Requirement


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)


Space Requirements

Workstation



Aisle Allowance


Departmental Service


Aisle Widths


Visual Management

Visual Management • Keterangan gambar:

A. Identification, housekeeping, and organization

1. Identification of the department

2. Identification of activities, resources, and products

3. Identification of the team

4. Markings on the floor

5. Markings of tools, racks, fixtures

6. Technical area

7. Communication and rest area

8. Information and instructions

9. Housekeeping tools

B. Visual documentation

10. Manufacturing instructions and technical procedures area

C. Visual production, maintenance, inventory, and quality control 11. Computer terminal

12. Production schedule

13. Maintenance schedule

14. Identification of inventories and work-in process

15. Monitoring signals for machines

16. Statistical process control

17. Record of problems

D. Performance measurement 18. Objectives, result, and difference

E. Progress status 19. Improvement activities

20. Company project and mission statement


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.

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