Layout Redesign to Eliminate Stagnation Using Blocplan to Increase Production Efficiency

Danny Wicaksono, Indra Setiawan, Fitriana Lestari Hasan

Abstract


The rapid growth of the automotive industry was also followed by growth in subsidiary companies. One of the subsidiary companies is a company that produces auto parts such as wheels. Sales volume in 2021 increased to more than 2 million products while for 2022 to April it was more than 1 million products. High demand is not accommodated due to inadequate production capacity, one of which is the machining area. This study aims to increase efficiency by redesigning the layout of the factory which is considered to increase production results in the machining area. The method used in this research is Block Layout Overview with Computerized Planning using Logic and Algorithm (Blocplan). The results showed that the redesign of the machining area could reduce stagnation by adding 1 unit of multi drill machine. Relayout in the machining area can reduce 93” time stagnation for the K2SA rear ABS type which can produce 2 outputs at once. The delay in the machining area can be reduced from 4,863 seconds to 0 seconds.


Keywords


blocplan, efficiency, layout, machining

Full Text:

PDF

References


Adiyanto, O., & Clistia, A. F. (2020). Perancangan Ulang Tata Letak Fasilitas UKM Eko Bubut dengan Metode Computerized Relationship Layout Planning (Corelap). Jurnal Integrasi Sistem Industri, 7(1), 49–56.

Afifah, N., Ngatilah, Y., Studi, P., Industri, T., Teknik, F., Pembangunan, U., Veteran, N., & Timur, J. (2020). Analisis Perancangan Ulang Tata Letak Fasilitas Produksi Dengan Metode Systematic Layout Planning (SLP) Di PT. Elang Jagad. Juminten, 1(4), 104–116.

http://juminten.upnjatim.ac.id/index.php/juminten

Al-Bayati, I. I., & Al-Zubaidy, S. S. (2021). A study to improve plant layout design for minimizing production costs. IOP Conference Series: Materials Science and Engineering, 1067(1), 012096. https://doi.org/10.1088/1757-899x/1067/1/012096

Amalia, R. R., Ariyani, L., & Noor, M. (2017). Perancangan Ulang Tata Letak Fasilitas Industri Tahu dengan Algoritma Blocplan Di UD. Pintu Air. Teknologi Agro-Industri, 4(2), 89–100.

Daya, M. A., Sitania, F. D., & Profita, A. (2019). Perancangan Ulang (re-layout) tata letak fasilitas produksi dengan metode blocplan (studi kasus: ukm roti rizki, Bontang). PERFORMA: Media Ilmiah Teknik Industri, 17(2), 140–145. https://doi.org/10.20961/performa.17.2.29664

Gogi, V. S., Rohit, D., Kiran, S., & Shaikh, S. M. (2014). Efficiency Improvement of a Plant Layout. International Journal of Innovative Research in Science, Engineering and Technology, 3(4), 11203–11209. https://doi.org/2014/4

Gosende, P. P., Mula, J., & Madroñero, M. D. (2021). Facility layout planning. An extended literature review. International Journal of Production Research, 59(12), 3777–3816. https://doi.org/10.1080/00207543.2021.1897176

Gunanti, N. A., Subagyo, A. M., Herwanto, D., & Arifin, J. (2021). Optimasi Tata Letak Fasilitas Menggunakan Algoritma Blocplan dan Corelap. Journal of Industrial and Manufacture Engineering, 5(2), 107–120. https://doi.org/10.31289/jime.v5i2.5555

Irwanto, A., Arifin, D., & Arifin, M. M. (2020). Peningkatan Kualitas Produk Gearbox Dengan Pendekatan DMAIC Six Sigma Pada PT. XYZ. Jurnal KaLIBRASI-Karya Lintas Ilmu Bidang Rekayasa Arsitektur Sipil Industri, 3(1), 1–17. https://doi.org/10.37721/kalibrasi.v3i1.638

Kovács, G. (2019). Layout design for efficiency improvement and cost reduction. Bulletin of the Polish Academy of Sciences: Technical Sciences, 67(3), 547–555. https://doi.org/10.24425/bpasts.2019.129653

Kovács, G., & Kot, S. (2017). Facility layout redesign for efficiency improvement and cost reduction. Journal of Applied Mathematics and Computational Mechanics, 16(1), 63–74. https://doi.org/10.17512/jamcm.2017.1.06

Lekan, O. K., Kayode, O. I., & Morenikeji, A. A. (2017). Analysis of Plant Layout Design for Operational Efficiency with Craft Algorithms. Acta Universitatis Danubius: Oeconomica, 13(4), 15–27.

Liu, H., Liu, X., Lin, L., Islam, S. M. N., & Xu, Y. (2020). A study of the layout planning of plant facility based on the timed Petri net and systematic layout planning. PLoS ONE, 15(9 September), 1–23. https://doi.org/10.1371/journal.pone.0239685

Mebrat, B., Assefa, L., Gezehagan, T., Achamu, G., & Balasundaram, K. (2020). Redesign the Plant layout for Efficiency Improvement and Cost Reduction: A Case Study. International Journal of Advances in Scientific Research and Engineering, 06(11), 46–54. https://doi.org/10.31695/ijasre.2020.33925

Mirzaei, N., Nejad, M. G., & Fernandes, N. O. (2021). Combining Line Balancing Methods and Discrete Event Simulation: A Case Study from a Metalworking Company. International Journal of Industrial Engineering and Management, 12(1), 14–24. https://doi.org/10.24867/IJIEM-2020-1-273

Satriyo, M., Arifin, M. M., & Agustin, M. (2017). Analisa Perbaikan Waktu Standard Proses Entrepot Di Departemen Logistik PT. Mercedes Benz Indonesia. Jurnal KaLIBRASI-Karya Lintas Ilmu Bidang Rekayasa Arsitektur Sipil Industri, 12(1), 16–40.

https://doi.org/10.37721/kalibrasi.v12i0.343

Setiawan, I., & Setiawan. (2020). Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study. Jurnal Sistem Dan Manajemen Industri, 4(2), 108–116. https://doi.org/10.30656/jsmi.v4i2.2775

Setiawan, Setiawan, I., Jaqin, C., Prabowo, H. A., & Purba, H. H. (2021). Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry. Quality Innovation Prosperity, 25(3), 48–64. https://doi.org/10.12776/qip.v25i3.1613

Sugiyono. (2017). Metode Penelitian Kuantitatif, Kualitatif, dan R&D (1st ed.). CV Alfabeta.

Tranggono, T., Rahmawati, N., & Resmi Hayati, K. (2021). Warehouse layout Design in Manufacturing Industry. International Journal of Eco-Innovation in Science and Engineering, 2(1), 14–19. https://doi.org/10.33005/ijeise.v2i01.36

Ulfiyatul, K., & Suhartini. (2021). Perancangan Ulang Tata Letak Fasilitas Produksi dengan Metode Systematic Layout Planning dan BLOCPLAN untuk Meminimasi Biaya Material Handling pada UD. Sofi Garmen. Journal of Research and Technology, 7(2), 151–162. https://journal.unusida.ac.id/index.php/jrt/article/view/556

Zhang, Y., & Khan, S. A. R. (2017). Importance of Warehouse Layout in Order Fulfilling Process Improvement. International Journal of Transportation Engineering and Technology, 3(4), 49–52. https://doi.org/10.11648/j.ijtet.20170304.11




DOI: https://doi.org/10.31315/opsi.v15i2.8023

Refbacks

  • There are currently no refbacks.


Bookmark and Share


Sekretariat :
Jurusan Teknik Industri
FTI UPN "Veteran" Yogyakarta
d.a Jalan Babarsari 2 Tambakbayan Yogyakarta 55281
Telp. (0274) 486256
Website http://jurnal.upnyk.ac.id/index.php/opsi
email : jurnal.opsi@upnyk.ac.id

 

indexed by:

 
 
 


Lisensi Creative Commons
This work is Licensed Under a Creative Commons Attribution 4.0 International license.

View My Stats