REDESIGNING LAYOUT OF KNITTING

PRODUCTION IN PT XYZ BY USING

COMPUTERIZED RELATIVE ALLOCATION OF

FACILITY TECHNIQUE (CRAFT)

By

Mohamad Jody Pratama

ID No. 004201200038

A Thesis Submitted to the Faculty of Engineering

President University in partial fulfillment of the requirements of

Bachelor Degree in Engineering Major in Industrial Engineering

2016

2

THESIS ADVISOR

RECOMMENDATION LETTER

This thesis entitled “REDESIGNING LAYOUT OF KNITTING PRODUCTION

PT.XYZ BY USING COMPUTERIZED RELATIVE ALLOCATION OF

FACILITY TECHNIQUE (CRAFT) ” is prepared and submitted by Mohamad

Jody Pratama in partial fulfillment of the requirements for the degree of Bachelor

Degree in the Faculty of Engineering has been reviewed and found to have satisfied

the requirements for a thesis fit to be examined. I therefore recommend this thesis for

Oral Defense.

Cikarang, Indonesia, March 13th

2016

Ir Andira, M.T.

3

DECLARATION OF ORIGINALITY

I declare that this thesis entitled “REDESIGNING LAYOUT OF KNITTING

PRODUCTION PT.XYZ BY USING COMPUTERIZED RELATIVE

ALLOCATION OF FACILITY TECHNIQUE (CRAFT)” is, to the best of my

knowledge and belief, an original piece of work that has not been

submitted, either in whole or in part, to another university to obtain a

degree.

Cikarang, Indonesia, March 13th

2016

Mohamad Jody Pratama

4

“REDESIGNING LAYOUT OF KNITTING PRODUCTION PT.XYZ BY

USING COMPUTERIZED RELATIVE ALLOCATION OF FACILITY

TECHNIQUE (CRAFT)”

By

Moahamad Jody Pratama

ID No. 004201200038

Approved by,

Ir Andira, M.T. Burhan Primanintyo, ST M.Eng

Thesis Advisor I Thesis Advisor II

Ir.Andira, M.T.

Program Head of Industrial Engineering

ABSTRACT

PT. XYZ is a manufacturing company that focused in textile raw materials of cotton

yarn and blended yarn into the raw material of T-shirts and polo shirts. In the last

several years, the production of company recorded a decline trend around 10-25

percent. This condition exists because there are arrangements of production that have

not been efficient, the activity relation between each department is far enough and

also backtracking. As the result the company's production costs are increase. This

study uses CRAFT as a layout improvements method and comparing the results of

each iteration. The results after using improvement the proposed layout is more

optimal and the reduction in material handling costs are 4.62% in the first iteration

and 7.97% in the second iteration. The total material handling cost of the company is

after implementing the second iteration as the lowest cost is Rp 152.963.424.

Keyword: Activity Relation, Backtracking, CRAFT, Facility Layout, Material

Handling Cost.

CHAPTER I

INTRODUCTION

1.1. Problem Background

The design of the facility has an enormous influence to the production of the

company because it is the basis of the entire production process. In the system of

production 20% -50% of the total manufacturing costs come from the material

handling costs and costs associated with the layout (Tompkins, 2010). By this reason,

Company requires a focused concentration to reduce the costs of production related to

the material handling and the costs that associated with the layout of the facilities.

PT. XYZ is a textile company that processes raw materials from cotton yarn and

blended yarn material into a shirt and polo shirt with the marketing area in some

Asian countries, such as Japan, Singapore and Hong Kong. The company starts the

production based on the order which means job order.

In PT. XYZ there are five departments, namely the raw material department, Dyeing

Yarn department, Knitting department, Piece Dyeing department and finishing

department. There are several types of fabrics that produced by PT. XYZ, which are:

knit fabric, print fabric, and a plain-colored fabric. One type of fabric that becomes

highest demand of this company is the knitted fabrics. Within a period of one year of

production knit fabric contributes 60% of the total production. Moreover, the knitted

fabrics that produced by PT. XYZ has a complex process passes through several

machines, i.e. from raw material department, the material then passes through the

process soft winding, dyeing, rewinding, knitting, bleaching, dyeing by using a

substance carrier, washing and drying, smoothing, finishing and packaging.

Complex process of knitted fabrics causes the flow of materials in production floor

should pass many points. Besides that, the facility layout of the company is not

arranged in the optimal can be seen in initial layout there are several backtracking in

flow process from Murata machine to Fukuhara and from Fukuhara to Coustic. It

makes the material movements are often create the problems such as the delay of the

material to transfer to the next department which resulted in piling up of material in

several departments. Another problem is the distance among of each department in

the PT. XYZ is far enough so it takes quite a long time in each process and material

handling cost will be increased.

1.2 Problem Statement

Based on the background that described above, then it is a problem in this study as

follows:

How to redesign the facility layout of knitted fabric production in PT XYZ?

1.3 Objective

The objective of this research is to reduce material handling costs by designing the

new facility layout in PT XYZ.

1.4 Scopes

Due to limited time and resources, there are several scope and limitation have to be

apply in order to achieve the target objectively:

1. The design layout is only done on the production facilities.

2. There is no new facility in layout design.

3. The cost for the change of layout is not considered.

4. The calculation of the distance between facilities using rectilinear.

1.5 Assumptions

Some Assumptions have to be applying in order to run this research properly:

1. The skill levels of the operator are same.

2. The production system as well as the flow of material does not change.

3. Material handling costs for forklift was Rp.588 per meter, and for box trolley

is Rp.648 per meter.

1.6 Research Outline

Chapter 1 Introduction

Background, problem statement, objective, scope, and assumption of

the thesis are contained in this chapter.

Chapter II Study Literature

The study literature contains a clear background and theoretical

grounding of the problem. This chapter provides all theory used to

solve the problem in this research and also giving supporting statement

to support the conclusion of the research.

Chapter III Research Methodology

This chapter consist of the steps that will be perform by the researcher

in order to know the problem in details, to get the data and how the

problem solving will be implement.

Chapter IV Data Collection and Analysis

This chapter is about the data gathered from the direct observation,

interview and it is used for analysis

Chapter V Conclusion and Recommendation

This chapter contains all summary results that have been performed by

the researcher. Most of it concludes the analyses made previously in

chapter five. The inputs for future research are also given.

CHAPTER II

STUDY LITERATURE

2.1 Facility Layout Planning

The layout is a major cornerstone in the industrial world. The layout of the plant or

facility layout can be defined as a procedure for setting factory facilities to support

the smooth production process. Facilities planning are a tool in the repair facility

layout, used in material handling (material handling). There are two important parts

in the planning of facilities i.e. location of the facility related to the plant site

planning and design of facilities that includes designing the structure of the plant.

With the layout of the facility so we can determine the general flow of the movement

of people and materials at the facility in question and have an important impact on the

efficiency of the operation. If based on the understanding that it means there is some

purpose of designing the layout of the facility that is.

a) Simplify the manufacturing process

b) Minimize the transfer of goods

c) Keeping the plant the flexibility to change production capability

d) Shorten the production process to maintain semi-finished goods peputaran

high

e) Lowering capital investment in equipment

f) Save the use of building space

g) Improving efficiency in the use of labor

h) Maintaining health and safety for workers

2.2 Types of Layout

One of the important decisions that need to be made in the design layout of the

facility is a decision determining the appropriate type of layout and efficiency of

manufacturing processes for a long enough period of time. The types of layout in

general is the Layout Product, Process Layout, Group Technology Layout, and

Layout by Fixed Position. On the production floor PT. XYZ uses the type of layout

based on the layout process. This layout is a method of placement machines and

production equipment of the same type into a single department. The advantage of

this type of layout is able to do a variety of types and models of products as well as

the specialization of work.

2.3 Algorithm Settlement Facility Layout

Algorithm to solve the problem of facility layout can be grouped into two, namely:

1. Heuristic Algorithm

This algorithm does not produce an optimal solution but nearly optimal, the

computing time is faster than the optimal algorithm. This algorithm is suitable

for designing the layout of the facilities for a large department or facility.

Based on the class, this algorithm is divided into:

a. Construction algorithm

This algorithm generates a facility layout starting from a blank layout.

The main difference from a variety of algorithms associated with the

construction of the criteria used to determine:

- The first to enter the facility layout

- The following facilities or facilities to be added to the layout, and

- The facilities of the first and subsequent in the layout.

Here are a few examples of the construction algorithm commonly

used:

1. MST (Modified Spanning Tree)

2. CORELAP (Computerized Relationship Layout Planning)

Is the first construction developed algorithms and computerized. This

is a qualitative input data into quantitative data and uses this

information to determine the first to enter the facility layout.

CORELAP calculate the total rating proximity (TCR) for each facility,

which balances the number of numeric indicator associated with this

facility.

3. PLANET (Plant Layout Analysis and Evaluation Technique)

b. Improvement Algorithm

Algorithm improvements require initial layout and data linkages

between departments. This algorithm produces a pretty good solution

for these algorithms consider the possibility if a department is placed

in a different location by changing the location of existing

departments. Disadvantages of this algorithm is the lack iteration so

often the resulting solution is still far from optimal. Some examples of

improvement algorithm is as follows:

a) 2-Opt

b) CRAFT (Computerized Relative Allocation of Facilities

Technique)

c) SA-CRAFT (Simullated Annealing - Computerized Relative

Allocation of Facilities Technique)

c. Mixed Algorithm (hybrid)

This algorithm combines the algorithm formation with algorithm

improvements. The initial layout using the algorithm formation then

the initial layout is corrected using the algorithm improvements.

The algorithm included in the algorithm of the mixture is

BLOCPLAN. BLOCPLAN algorithm can be used both as construction

and repair algorithms.

2. Optimal Algorithm

According to Heragu Sundereesh, there are three classes of optimal

algorithms to solve the QAP, namely: Algoritma Branch and Bound

a. Algoritma Decomposition

b. Algoritma Cutting Plane

QAP (Quadratic Assignment Problem) is the most common form of

formulations in the mathematical model layout problems. As the name

implies, the QAP is a problem with the placement of the objective function is

a function of two levels (quadratic) of several variables. While the function of

the constraints is a linear function of several variables. QAP formulation

requires a number of facilities and the number of the same location. If the

number of locations over the number of facilities then the solution obtained is

not feasible.

2.3.1 Comparison Program Layout

Many methods can be used to plan the layout of the facility. Some of them are

computerized methods, such as CRAFT, CORELAP, ALDEP, and PLANET.

According to Apple (1990) some of the advantages and disadvantages of each

computerized algorithm is as follows:

1. CRAFT

CRAFT technique first introduced by Armour and Buffa in 1983 that aims to

minimize the cost of material movements, where the costs of moving material

is defined as the flow of products, the distance and cost of transport unit.

Table 2.1 CRAFT

ADVANTAGES DISADVANTAGES

1. Allow the establishment of

a special location

2. The input format can vary

3. Time short computer

4. Having a mathematical

sense

5. Can be used for office

layouts

6. Can check previous work

7. Costs and savings printed

1. Results can not be directly used

2. Programs tend to have short-

distance vision, can not find the

best answer by simply changing

two or three departments

3. Changing departments should: (1)

the same size, (2) adjacent to each

other (3) bordering the same

department

4. Require clarity of the structure of

input data

5. The draft letter is difficult

6. It does not produce the initial

layout

7. Better reassembled

8. Unexpected connection is not

taken into account

9. Limited to 40 departments

2. CORELAP

CORELAP is an acronym for computerized relationship layout planning. It

generates a layout on the basis of total closeness rating (TCR) for each

department.

Table 2.2 CORELAP

ADVANTAGES DISADVANTAGES

1. Easy to run in the computer

2. Forming a new layout

3. Limitation of inputs and the

same finish

4. Based on the linkage map

5. Each step can be seen during

the development of the layout

6. Most linkages are shown in

both

1. Unable to determine location

of activity remains

2. Not counting the cost

3. Limited to 45 departments

4. Shape layout is not 'orderly'

3. ALDEP

ALDEP first developed by Seehof and Evans in 1967. The next development

undertaken by the company at IBM. The working principle is based prefensif

ALDEP such activity relationship CORELAP algorithm.

Table 2.3 ALDEP

ADVANTAGES DISADVANTAGES

1. Can determine specific

locations within the limits of

available space

2. Solving the identified areas

3. Develop many choices

4. Very into account the linkages

1. Switching costs are not

calculated

2. Relationships that are not

expected to go unnoticed

3. Assessment methods are

questionable

4. The difficulty in assessing the

production process

5. Order room demands are not

taken into account

6. Limited to 53 departments

4. PLANET

PLANET is a heuristic algorithm in the planning of the facility to produce

AAD (Area Allocation Diagram). The principle works is putting all of the

facilities or departments in one location are still vacant in accordance with the

scale of the area of each.

Table 2.4 PLANNET

ADVANTAGES DISADVANTAGES

1. Based on the map from - to

2. Using material removal costs

for certain displacement

means for each displacement

in the order of operations

3. Require interaction between

the computer and the engineer

to train the judgment

4. Can be applied to any

problem that includes a

combination of activities that

could be the apparently with

numbers

5. Can set the location of certain

activities and characteristics

of the building

6. There is no required input

layout

7. Print a handling fee for each

'relations activities' plus the

total removal costs

8. Using the term ordinary

factory and ordinary factory

data as input

9. Allows selecting the selection

and placement department

1. Useful for the layout of the

production is not for the

service department

2. Requires application and real

experiments

3. Data input which requires

arrangement (but not more

than is typically collected by

the usual layout)

2.3.2 Computerized Relative Allocation of Facilities Technique (CRAFT)

CRAFT technique first introduced by Armour and Buffa in 1983 that aims to

minimize the cost of material movements, where the costs of moving material is

defined as the flow of products, the distance and cost of transport unit.

Changes between departments is expected to reduce the cost of material movements.

CRAFT make the exchange consideration for the layout of the new department, and

this is done repeatedly - again to produce the best layout and taking into account the

cost of material movements.

Data required CRAFT among others (Purnomo 2004):

1. Initial Layout

Information needed from the initial layout is data on the number of facilities and the

area of each facility

2. Data flow

Data flow of material in a production floor can be obtained from FTC (from to chart).

FTC is one of the latest techniques used in layout work and the removal of material.

Usually very useful if the goods flowing in a region in large numbers, such as

workshops, offices, or other facilities. The FTC is also useful if the relationship

occurs between the number of activities and if desired their optimum activity

planning.

Some advantages of using the FTC is:

a) Analyzing the material displacement

b) Planning flow patterns

c) Determining the location of activities

d) Benchmarking the flow pattern or layout replacement

e) Measurement efficiency of the flow pattern

f) Shows the dependence of the activity with other activities

g) Indicates the volume of displacement between activities

h) Shows a cross linkage of production

i) Indicate the possibility of production control problems

j) Shows the quantitative relationship between the activity and the displacement

k) Shortening travel distances during the process

There are some considerations and reasons to use CRAFT in designing the layout of

manufacturing facilities, as follows:

1. In this study, the material flow is very dominant factor to be considered in

designing the layout of the factory facilities more efficient at PT. XYZ.

Yardstick used in achieving a more efficient state is minimizing material

handling costs. Therefore, CRAFT suitable to be applied, because one of the

criteria used in CRAFT is minimizing the cost of material handling.

2. At PT. XYZ there are enough facilities or work stations. Therefore, the

CRAFT can be applied in this study, because it can make up to 40 facilities.

3. The advantages of CRAFT is able to resolve the problem by swapping

departments of different sizes. And can redeem two or three departments at

once and produce a more efficient layout. Therefore, CRAFT can be applied

to the PT. XYZ which has a vary size of work stations in designing the layout

of the factory facilities more efficient.

2.4 Material handling

2.4.1 Definition Material Handling

One of the important problems in the production process is the movement of material

from one level to the next production process is referred to as material handling.

Material handling has meaning not only transferring material. Material Handling has

meaning material handling just the right amount of material to comply in good time at

a suitable place, at the right time in the right position, in the appropriate sequence and

a low cost by using the correct method.

Factory layout planning can not ignore the significance the activity of the material

removal or material handling, otherwise it is impossible to apply effectively the

material transfer system without regard to the common problems encountered in the

planning layout. In most manufacturing processes, material handling is an very

important activity.

2.4.2 Distance Material Handling

There are some systems that are used to calculate the distance between two points

amid one location to another location coordinates indicated as (x, y) and (a, b),

among others, the euclidean, rectilinear, and the square euclidean. In this research

will be discussed further on the size of the rectilinear distance, which is the distance

measured perpendicular to follow the path of the center point to center point facilities

other amenities. How to determine the rectilinear distance of the facility to other

facilities using the following formula (Purnomo, 2004: 80-83)

dij = |xi – xj| + |yi – yj| (2-1)

xi : the x-coordinate at the center of the facility i

xj : the x-coordinate at the center of the facility j

yi : the x-coordinate at the center of the facility i

yj : the x-coordinate at the center of the facility jfu

dij : the distance between the center of the facility i and j

2.4.3 Engineering Planning and Material Flow Measurement

Settings departments within a factory is based on material flow between production

facilities or those departments. To evaluate alternative design of the layout of the

department, the necessary act of measuring the flow of materials in a technical

analysis. There are many analytical techniques that can be used to analyze and

evaluate the flow of materials. The analysis techniques are divided into two

categories: (Purnomo, 2004):

1. Conventional Methods

This method has been used for many years, it is relatively easy to use and

commonly used way is a graphical form. Overall better than the conventional

techniques of quantitative analysis techniques to be used to analyze the flow

of input materials for use quantitative and qualitative input. Some of the tools

used in conventional analysis techniques are Assembly Chart, Operation

Process Chart, Chart Process, Process Flow Chart, Multi Product Process

Chart, From To Chart, and Flow Diagram

2. Quantitative Methods

This method is a modern analytical techniques using statistical methods and

mathematical complex and more sophisticated, and are generally classified as

operational research. This method often had to use the help of specific

computer programs in performing complex calculations. Examples of

quantitative analysis technique is simulated annealing, quadratic assignment

problem, and genetic algorithms.

In this study, two kinds of tools will be used conventional techniques to analyze the

flow of materials, namely Process Flow Chart and From To Chart.

2.4.3.1 Flow Process Chart

Process Flow Chart is a schematic or diagram that shows all the steps in a process of

operation, inspection, transportation, and storage waiting that occurs during an

ongoing process and shows how the move was mutually hold interaction with one

another. Additionally Process Flow Chart also contains information that is required in

the analysis, such as the required time and distance moved. Several usability of

Process Flow Chart is as follows (Purnomo, 2004):

1. Showing all the steps and tests in a process in detail

2. Used to analyze a process

3. As a tool for process improvement or working methods

4. As a basis for calculating the cost to search for the hidden costs in case of

inefficiency in work

5. Used as a comparison, if there is a substitute method

2.4.3.2 From To Chart

From To Chart is a conventional technique used in the planning layout and material

moving. Generally From To Chart used in designing the plant layout is based on the

flow process. The principle applied in the analysis of material with From To Chart is

trying to find the minimum total material handling cost:

1. Material with a weight / volume move large distances as short-nutshell. The

sequence of processes (related to the production facility layout) is set in

accordance with the provisions of this

2. As far as possible be avoided from the backflow (backtracking) because it

causes material handling activities must be carried out twice a step activities.

2.5 Systematic Layout Planning (SLP)

Richard Muther develops layout planning method called Systematic Layout Planning

(SLP). Factory layout planning procedure according Muther's Systematic Layout

planning systematically Procedure can be seen in Fig 2.1.

Data Masukan dan

Aktivitas

Aliran Material Hubungan Aktivitas

String Diagram

Kebutuhan LuasKetersediaan Luas

Area

Space Relationship

Diagram

Modifikasi Layout Batasan Modifikasi

Perancangan

Alternatif Layout

Evaluasi

Fa

se

An

alis

isF

ase

Sin

the

sis

(De

sig

n P

roce

ss)

Fa

se

Pe

mili

ha

n

Alte

rna

tif

Figure 2.1 Implementation Procedures Systematic Layout Planning

From the procedure in Figure can be seen that the first step begins with the collection

of data used in the planning layout. Once the required data is collected, the material

flow analysis will be done in combination with analysis of activity (activity

relationship) that will be used to make the connection diagrams activity (activity

relationship diagram). Moreover, at this stage of this analysis will also consider the

needs of the area required by the wide availability of areas for planning the

manufacture of the Space Relationship Diagram.Based on the Space Relationship

Diagram is augmented by doing some modifications as necessary and determine the

practical limitations of alternative layouts can be designed and evaluated. Five initial

step in this procedure is the stage of analysis of the problems that have been

formulated. Then, the sixth step to planning an alternative layout phases of research

required for the planning process. While the last stage is the selection process is to

evaluate the alternatives that have been designed layout.

2.5.1 Routing Sheet

In designing a facility it is necessary to establish production capacity of an enterprise.

This is done to anticipate a short period of operation in which the size of the factory

cannot be changed. A basic step in setting a good production system is to determine

the number of machines or production equipment needed appropriately. Data

necessary to determine precisely the number of machines is as follows (Sritomo,

2000):

1. The volume of production is achieved

2. Estimated scrap (defective products) at each process

3. The value of the efficiency of each machine

The efficiency value can be calculated by:

E = 1- (Dt + St) / D; where E = the efficiency, Dt = down time, D = working time per

period, St = set up time for work per period.

4. The standard time for the process of ongoing operations

In the calculation of the standard time is also calculated allowance is usually

expressed in%. Calculation% allowance is obtained based on the data of field

observation immediately considered the same for all production.

After that the value obtained by calculating the number of engines:

(2-2)

Where,

P = the number of products to be made by each machine per working time

T = total processing time required for production operation process obtained from the

time study or theoretical calculations

D = hours of engine operation provided

E = efficiency factor machines work caused by the setup, break down, repair, or other

things that cause idle

N = the number of engines or carriers needed for production operations

2.5.2 Relationship Diagram room

In the process of making the connection diagrams of the room, you need to do is

evaluate the area needed for all activities of the company and the area available. The

design layout work facility, ideally made in advance, while the factory building was

established in accordance with the design layout of the facility that has been made.

Connection diagrams room can be made after comprehensive analysis of the needs

and combined with Activity Relationship Diagram.

1

CHAPTER III

RESEARCH METHODOLOGY

3.1 Theoretical Framework

Figure 3.1 Theoretical Frameworks

• Identify problem from production floor

• know the problem statment

• understand the objective of solvingthe problem,scope, limitation and assumption

PROBLEM IDENTIFICATION

• Facility Layout planning

• Types of layout

• Algorithm settlement facility layout

• CRAFT

• Material handling

LITERATURE STUDY

• Flow of material

• Existing facility layout

• Frequency of material transfer

DATA COLLECTION

• From to Chart

• Flow diagram Chart

• Routing Shett

• ARC

• Material handling cost

• Election alternative layout

• Anlysis of proposed layout

DATA CALCULATION AND ANALYSIS

• Conclude the result of data analysis

• Compare the objectives and conclusion

• Recommend the advice for future research

CONCLUSION AND RECOMMENDATION

2

Figure 3.1 shows the theoretical framework of this research. The theoretical

frameworks consist of Observation, Problem Identification, Literature Study, Data

Collection, Data Calculation and Analysis and last Conclusion and Recommendation.

The explanation of theoretical frameworks is explained in the following sub chapter

which is detail research frameworks.

3.2 Initial Observation

Initial observation this research started from material movements in XYZ. There are

some problems which resulted in higher material handling costs in XYZ as a

backtracking, buildup material (bottleneck) that is not optimal and the distance

between departments. The observation is done by means of direct observation of the

production floor, interviews with management. After collecting the data, the main

cause will be the main focus for reducing material handling costs. As stated

previously, high cost of material handling caused a buildup of material, the distance

between the department and material handling equipment that is not optimal.

Therefore the main aim of this research will be achieved is to make a displacement

material system better than that already exist today.

3.3 Problem Identification

After the initial observation conducted, problem identification is the following step.

The problems identification will help to identify and analyze the initial observation

result. Problem identification will also help in narrowing the concept of this research

to be properly conducted and the following results in identifying and analyzing the

methods will be best presented as the objectives of this research. The background of

this issue was supported by a strong theory, trying to identify and analyze the right

variables that directly and indirectly affect the expensive material handling costs.

This research was deliberately done to identify problems that exist through several

methods; this research will determine the movement of material, company layout that

is used to reduce material handling costs.

3

3.4 Literature Study

Literature study is the basic knowledge and science of this research is conducted and

executed. The literature study helps the researcher to define, determine and reveal the

data collection to be well represented and understand by expert and non-expert.

Literature study has an important role as guidance to reach and accomplish the goal.

The literature study will also provide several theories that will strengthen the analysis

of the observation and the results of this observation will be valid and officially

examined through conducted observation by determining several theories and

terminologies. Literature study in chapter II discusses about the method that used to

interpret and examine the data to be reliable and valid to be proved also can be easily

read. The literature study consists of facility layout and material handling as basic

theory of this research conducted. In collecting literature studies, there are several

activities that needed to be done. First of all, the researchers have to read several

book related to the topic.

3.5 Data Collection, Calculation and Analysis

3.5.1 Data Collection

At this stage of data collection is done collecting relevant data and takes as input the

preparation of material transfer system later. Input data required include:

1. Data transfer will show the initial flow layout and direction of transport flows

that occur in existing material transfer system in PT. XYZ.

2. Data production process as a reference for the preparation of proposals related

to the production output and production processes directly illustrates the flow

of material movements. This production data including the operation process

chart

3. Data production facility is an equipment data contained in the company's

production machinery and transport equipment. This data is the data that will

be used for the calculation of activity cost determination for each piece of

equipment has the burden of costs that vary.

4

4. Data production output and capacity of MHE, the data show the number of

outputs in one cycle of production and material transportation capacity so as

to know the number of frequencies required in a day.

5. Data transfer material is data that describes the specification of the

displacement was conducted on the equipment used, the amount of frequency,

how much transportation and frequencies required in a month. The number of

frequencies generated will affect the amount of time needed.

3.5.2 Data Calculation

At this stage the data input to the CRAFT so prepared and processed into a form that

can be processed. Data processing itself through the process as follows:

1. Flow Diagram chart

2. Activity Relation Chart

3. Routing sheet

4. From to Chart

5. Material Handling Cost

3.5.3 Data Analysis

1. Election Alternative Layout

At this stage it will be evaluated the initial layout with the layout of the alternative

selected. This evaluation was conducted to determine the ratio between the initial

layouts with alternative layout has been made. Layout proposal will produce a more

efficient layout by having the distance moved closer and it will reduce material

handling costs.

2. Analysis of Proposed Layout

Analysis at this stage is a process of proving that the alternative layouts are selected

according to the desired result.

5

3.6 Conclusion and Recommendation

The conclusion started from giving the result of data calculation and analysis. The

result of data calculation and analysis will answer research questions as the problem

statement in Chapter I.

6

Initial Problem

Observation to production

floor

Flow of material

Exiting facility layout

Frequency of material transfer

Problem identified

Frequency of material

Transfer Cost MHCRouting sheetFlow Diagram

ChartCRAFT

Data analysis

Alternative layout

Conclusion of MHC

Data Calculation

Data Collection

Distance

Figure 3.2 Detail Research Frameworks

CHAPTER IV

DATA COLLECTION AND ANALYSIS

4.1 Data Collection

4.1.1 Current Condition of Material Movement

In material transfer system planning, the main data that is needed as the object of

research is data transfer method, the specification unit load of material

movements, and supporting equipment transfer facilities. The initial data of

material movement is used as a reference to be compared with the proposed

material movement to solve material handling problems in PT. XYZ. This data is

also supported by the direction of the material that moves from the initial position

to the next station.

2

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

5

78

8

9

10

Musholla

Control Room

OFFICE &

ADMINISTRATIONDept. Bahan

BakuGudang

Bahan Sisa

Dept. Produk

JadiDept.

Printing

Dept.

Printing

Dept. Finishing

Maintanance

Service

Tower Air

Dept.

Knitting

Gerbang

Utama4

1

1

Forklift

Box Manual

Softwi ndi ng

1

Softwi ndi ng

2

1

2

3

3

Box Manual

3

4

Dyei ng

Machine6

5

6

7 88

7

9

5

6

Dept.

Knitting

Pantry

Service

Service

10

8

Dept. Piece Dyeing7138

9

9

14

15

9

10

10

16

17

Dept. Finishing

Parkir Mobil

Parkir Motor

Keterangan :

1 = Yung Chi Machine

2 = Hisaka Machine

3 = Murata Machine

4 = Fukuhara Machine

5 = Coustic Machine

6 = Winch Machine

7 = STR Machine

8 = Stenter Machine

9 = Cutting

10 = Packing & QC

= In

& Out

= Process

Inspection

= Storage

Transfer

= Crash

= Backtracking

Transfer Flow

Figure 4.1 Current Layouts and Flow of the Company

Figure 4.2 Current Layout of the Company

In the figure 4.2 above the scale is 1:10 and the picture shows the backtracking

and cross tracking that is marked with a red circle and a red dotted line. One of the

criteria of a good flow in material movement is the number of backtrack and cross

tracking is minimum.

4.1.2 Current Production Facility

Table 4.1 shows the number of department in PT.XYZ and describe machine in

each department. In table 4.1 also show the number of machine and function of

each machine.

Table 4.1 Machine in Production Floor

Department Machine Number of

Machines Function

Department Yarn

Dyeing

Yung

Chi 7 A roll of yarn cones to cheese

Hisaka 9 Yarn dyeing process by inserting a tube into

the dyeing

Murata 2 Curl yarn of cheese cake cones

Department

Knitting Fukuhara 42

Knitting (produce some kind of fabric using

yarn materials)

Department

Finishing Coustic 1

Administration of drugs in order to color the

fabric more concentrated

Department Piece

Dyeing Winch 7

Flushing of dirt when finished knitted

fabrics like from stains, wax, and other

Department

Finishing

STR 1 The ripening process (to harden and smooth

out the fabric)

Stenter 2 gramasi fabric

Table 4.2 describes material handling equipment in PT.XYZ. In this table also

shows the number of equipment with the function and location of the use of

equipment.

Table 4.2 Material Handling Equipment in Production Floor

Name Quantity Function Location

Forklift 3

Tool material movements with

weights in large numbers about 1.5 -

3, 5 tons per one transport

Raw material to Softwinding

Rewinding to Knitting

Knitting to Coustic

Pallet 120 For transporting materials in large

volumes and can be classified Warehouses and Softwinding

Box

Trolley 23

Move material with a certain volume

through land All locations except Warehouses

4.1.3 Production Process Data

PT. XYZ produces several types of manufactured products such as knit fabric,

print fabric and colored plain fabric, but the focus of this research is aimed at the

knit fabric, because the knit fabric is the product with the highest demand. The

description of the production process at PT. XYZ on knitted fabrics can be seen

below.

1. Loading the raw material from the warehouse to the production floor.

The raw materials used are blended yarn which is a mixture of cotton yarn

with rayon or polyester. This yarn is taken from the warehouse and

transferred to the department of Yarn Dyeing.

2. Softwinding

The next process is softwinding. It is the process of winding the yarn from

cones into cheese. One roll of gray yarn can generate two gray yarns

cheese.

3. Dyeing colors

Yarn dyeing process that has been winded into the cheese is placed on the

carrier tool. After the cheese is inserted into the carrier and locked tightly,

then the carrier is lifted by using a crane machine and put into the

immersion tube. The color in dyeing process is chosen based on the order

of customer. There is also a drying process, which is the carrier is inserted

into the dryer machine.

4. Rewinding

Rewinding is a winding process of yarns from cheese to cones after the

yarn is dyed. Cones used for rewinding is different with the cones in the

sofwinding process. Two pieces of cheese will produce one cone of yarn

5. Knitting

Knitting process produces several types of fabrics by using blended yarn

materials. In this process there are two sub-sections as follows:

Sub-section knitting gray cloth

Sub-section striper knitting fabric which is knitted by using yarn dyed

6. Adding liquid material

At this stage the fabric is processed by giving a liquid material for the

bleaching process at the next machine.

7. Bleaching

Bleaching process aims to eliminate the dirty material from the fabric such

as stain, wax, etc.

8. Washing and Steam Heating

The process of washing and drying the fabric fibers is done twice by using

STR machine and stenter machine. In the STR machine, fabric is dried

using hot steam. Then on stenter machine, the fabric is dried again and

smoothed before packed.

9. Finishing and Packaging

Final check is done before the fabric is delivered to the department of

finished product. Fabric is wrapped and labeled to make it easy in delivery

process to the customer.

4.1.4 Flow Process Chart

From the figure 4.3, circle symbol means the operation, the arrow symbol means

material displacement, square symbol means the inspection, the semi-circle

symbol means in-process delay (holding) and the last triangle symbol means

warehouse.

Figure 4.3 Flow Process Chart

4.1.5 Routing Sheet

The initial step in data processing is making calculations Routing Sheet. Routing

sheet is used to calculate the number of machines and the number of parts that

must be prepared for a number of the desired finished product. Data needed on

Routing Sheet consists of the data flow of the production process, the production

of the required amount, the efficiency of the engine and also a production process

of each material through a series of processes. In the routing calculation sheet,

there are some assumptions, such as the provision of the efficiency of each

machine. Table 4.3 shows the routing calculation sheet.

The columns contained in the routing sheet are as follows:

Column 1 : The sequence number of operations of each component flowing.

Column 2 : Name of the operations performed

Column 3 : The machine used in the production process.

Column 4 : Process time in production process showed in minutes. The value

comes from measurement and it is set as the target for each

process.

Column5 : Theoretical engine capacity of each machine that supports the

production process. Theoretical machine is based on machine

specification.

Column 6 : Number of expended output in whenever production

Column 7 : Efficiency machines (%)

Column 8 :The capacity of the actual machine from any machine that

supports the production process.

Formula = theoretical engine capacity (theoretical engine capacity

* (1-efficiency engines))

Column 9 : Number of products should be prepared

Column 10 : The need for theoretical and actual engine

Formula (Theoretical) = Number of prepared / theoretical machine capacity

Formula (Actual) = Number of prepared / actual engine capacity

Table 4.3 Routing Sheet

No.

(1)

Name of the operation

(2)

Machine

(3)

Process

time

(minute)

(4)

Theoretical

Capacity

Machine

(kg)

(5)

Output

one

process

(kg)

(6)

Efficiency

Machine

(7)

Actual

Engine

Capacity

(kg)

(8)

Demand

(kg)

(9)

Machine needs

Theoreti

cal

(10)

Actual

(11)

1 Arrange yarn to Yung chi

machine

2 Softwinding process Yung

Chi

80 11040 80 95% 10488 92000 8,77193 9

3 Compile a collection of yarn in

the form of cheese into the carrier

4 Color dyeing process

Hisaka 310 11752 330 95% 11164,65 92000 8,24029

8

9

5 Drying process Hisaka 70 22080 140 95% 20976 92000 4,38596

5

5

6 Preparing process of rewinding

7 Rolling the yarn of cheese to

cones

Murata 80 11040 80 95% 10488 92000 8,77193 9

8 Preparing yarn before entering

into the knitting process

9 Arrange yarn based on color

orders

10 Perform set-up machine

11 Conducting the knitting process Fukuhara 420 1840 70 95% 1748 92000 52,6315

8

53

28

No.

(1)

Name of the operation

(2)

Machine

(3)

Process

time

(minute)

(4)

Theoretic

al

Capacity

Machine

(kg)

(5)

Output

One

process

(kg)

(6)

Efficiency

Machine

(7)

Actual

Engine

Capacity

(kg)

(8)

Demand

(kg)

(9)

Machine need

Theoreti

cal

(10)

Actual

(11)

12 Administration of drugs for

washing bleaching

Coustic 45 73600 300 95% 69920 92000 1,31578

9

2

13 Washing process Winch 80 41400 300 95% 39330 92000 2,33918

1

3

14 Washing process to remove

residual drug

STR 35 32200 300 95% 30590 92000 3,00751

9

4

15 drying with hot steam

16 drying process Stenter 40 36800 300 95% 34960 92000 2,63157

9

3

17 Cutting process based on order

18 A final check for color and size

19 Packing

29

Based on the routing calculation sheet in Table 4.3, the number of machines

required to produce knitted fabric is determined. The result obtained from the sum

of the theoretical machine of each machine used to produce knitted fabric for a

period of one working day (8 hours). Here is the number of machines required in

the manufacture of knitted fabrics.

Table 4.4 Summary Machine Needs

Name of machine Quantity

Yung Chi 9

Hisaka 14

Murata 9

Fukuhara 53

Coustic 2

Winch 3

STR 4

Stenter 3

4.1.6 Data Frequency of Material Movement

Frequency of material movement is the amount of material delivery from the

starting location to the destination location in days, weeks or months. The

frequency of the data transfer between the existing material and activity between

machines in the production process is required in the preparation of a from-to

chart. Data transfer frequency of this material is a quantitative measure for each

movement of material movements between machines that is traversed in the

whole production process. The calculation of the frequency shift is done by using

the movement of the yarn material blended from the main warehouse to

warehouse of finished products. The average amount of demand for this product

(knit fabrics) in one month is 92 tons. In the table 4.5 below, it can be seen the

frequency displacement of blended yarn material at PT. XYZ as follows.

Table 4.5 Frequency of Material Transfer

From To Demand

Per Day

(Kg)

Existing

Material

Transfer (Kg)

Frequency of

Material

Transfer Per

Day

Frequency of

Material

Transfer Per

Month

Warehouse Softwinding 4000 400 10 230

Softwinding Dyeing 4000 200 20 460

Dyeing Rewinding 4000 200 20 460

Rewinding Knitting 4000 400 10 230

Knitting Coustic 4000 400 10 230

Caustic Winch 4000 200 20 460

Winch STR 4000 200 20 460

STR Stenter 4000 200 20 460

Stenter Finishing 4000 200 20 460

Finishing Packing 4000 200 20 460

Packing Finished

Goods

Department

4000 200 20 460

4.1.8 From-To Chart

Figure 4.4 shows the results from to chart is used to input into CRAFT to

calculate the cost of material handling in the initial layout and propose layout

Figure 4.4 from-To Chart

From\To Dept 1 2 3 4 5 6 7 8 9 10 Ship Total

Dept 3651480 0 0 0 0 0 0 0 0 0 0 3651480

1 0 1415880 0 0 0 0 0 0 0 0 0 1415880

2 0 0 2235600 0 0 0 0 0 0 0 0 2235600

3 0 0 0 5916750 0 0 0 0 0 0 0 5916750

4 0 0 0 0 6085800 0 0 0 0 0 0 6085800

5 0 0 0 0 0 3726000 0 0 0 0 0 3726000

6 0 0 0 0 0 0 3726000 0 0 0 0 3726000

7 0 0 0 0 0 0 0 4620240 0 0 0 4620240

8 0 0 0 0 0 0 0 0 1788480 0 0 1788480

9 0 0 0 0 0 0 0 0 0 1937520 0 1937520

10 0 0 0 0 0 0 0 0 0 0 7452000 7452000

Ship 0 0 0 0 0 0 0 0 0 0 0 0

Total 0 3651480 1415880 2235600 5916750 6085800 3726000 3726000 4620240 1788480 1937520 7452000 42555750

Matrix of Transfer Distance

Table 4.12 Dimension Engineering and Room

No Facilities

Number

of

machine

Dimension (meter) Size And Allowance Total

area

(m2)

Size

Requirements

Existing

Area (m) Area

(m2)

Centroid

Long Wide Area (m2) employee Area

p l X Y Material

Office - - - - - - - - 22 69 1518 11 34,5

Raw material - - - - - - - - 27 69 1863 13,5 34,5

1 Yung Chi 7 8,2 1,1 9,02 3,608 2,706 15,334 107,338 12 30 360 6 15

2 Hisaka 9 2,5 1,3 3,25 1,300 0,975 5,525 49,725 21,5 30 645 10,75 15

3 Murata 2 9,1 1,1 10,01 4,004 3,003 17,017 34,034 21,5 15 322.5 10,75 7,5

4 Fukuhara 42 2,5 2,5 6,25 2,500 1,875 10,625 446,25 23 101 2323 11,5 50,5

5 Coustic 1 3 2,5 7,5 3,000 2,250 12,750 12,75 30 18 540 15 9

6 Winch 7 3,3 1 3,3 1,320 0,990 5,610 39,27 43 30 1290 21,5 15

7 STR 1 16,5 4,2 69,3 27,720 20,790 117,810 117,81 30 18 540 15 9

8 Stenter 2 2,8 2,2 6,16 2,464 1,848 10,472 20,944 17 36 612 8,5 18

9 Finishing

- - - - - - - - 17 24 408 8,5 12

10 Packaging

- - - - - - - - 30 24 720 15 12

11 Finished goods - - - - - - - - 25 69 1725 12,5 34,5

- Remaining ingredients - - - - - - - - 15 69 1035 7,5 34,5

- Printing 1 - - - - - - - - 15 101 1515 7,5 50,5

- Printing 2 - - - - - - - - 15 69 1035 7,5 34,5

- Maintenance Room - - - - - - - - 14,5 20 290 7,25 10

- Service Room - - - - - - - - 14,5 20 290 7,25 10

- Water Tower - - - - - - - - 14,5 20 290 7,25 10

32

The given allowance is qualitative. It is adapted to the conditions on the ground

observations. Here is the explanation of the provision of allowance in each

activity:

1. Yung Chi Machine, this machine has long enough size. Material from the

warehouse before entering into this machine will be placed in front of the

room. In this activity the material that comes is in still in the form of yarn

in cones. Then cones of yarn-cones will be transferred to the cheese by

using machines Yung Chi. Yung Chi One machine can produce 60 cheese

yarns. Employee activities that occur around the engine area are to make

the process of monitoring of the flow of material. Therefore, the activities

of employees on this machine are still very intensive. The allowance given

to employees are 0.3 and 0.4 for the material.

2. On the machine Hisaka, the large number of machines required in the yarn

dyeing process also causes the working conditions for this area quite

intensive, so it is given a value of 0.3 allowances for employees and 0.4

for the material. After experiencing the process of material coloring on this

Hisaka engine, the output of these machines will be transported by the

carrier to enter the next process. This process also requires trained

employees to process material adjustment to the transport carrier.

3. Murata Machine, after the material is processed on a machine Hisaka,

material output in the form of cones is threads in the aluminum coils. Then

the cones will be positioned into the machine Murata. Basically this

machine gives allowance based on the amount of material that goes to the

employees of 0.3 and 0.4 for the material.

4. Knitting Machine, basically gives allowance based on the amount of

material coming from the engine Murata. All material will step through

this activity to the process of knitting yarn so later, the obtained spools of

thread are finer than before and the pattern of color made to order. For

employees, the mobilization needed here is quite high, because the

machine was composed of 200 spinners and need to be checked every

process, so the allowance given to employees is 0.3 and for the material is

0.4.

5. On Caustic machine, the size of the material on this activity has become a

roll of cloth; auto previous quantity of material that goes into these

machines became more and more. Same with previous activities, for

employees are given the allowance value of 0.3 for employees and 0.4 for

the material.

6. On Winch machines, the task of the employees in the activity of this

machine is to pay attention and make sure that the bolts of cloth had been

submerged by water to remove residual bleaching medication from the

previous engine. Value allowance granted to employees was 0.4 for Winch

This machine has a size that requires long enough leeway for movement of

workers in performing their duties. Material allowance value is given a

value of 0.3 for the number of machines that made a lot of material

waiting to be processed becomes less so that the material that has been

completed through the process in winch the machine can be directly

positioned on STR machine for further processing.

7. In the STR machine there are two processes, namely the final washing and

drying the fabric fibers. There are two processes in this machine causes the

activity of employees on these machines should be given sufficient

allowance, amounting to 0.4 and 0.3 for the material.

8. Stenter machine, this machine is the latest machine through which the

material before finally do quality control and packaging. In this machine

there are some material waiting to be processed because of the amount of

material that goes quite a lot, so it is given to material allowance of 0.3

and 0.4 for employees.

4.1.9 Calculation of Cost Material Handling

To provide smooth operation in operational activities of the production process, it

needs to be supported by understanding of conveyance or transportation between

the (department) or within the department itself. In this study, conveyance transfer

materials used in PT. XYZ consists of four types, they are:

1. Man

2. Forklift

3. Pallets

4. Box Trolley

Data needed in the calculation of this Material Handling Cost includes a data

sequence of the production process, the weight of material moved, material

handling tools used, and the cost of material movements per meter. To find the

great total material handling costs, it can be determined by adding the fixed cost

and variable cost. Calculation of fixed costs is derived from the overall total cost

incurred on each tool used in displacement of material. Variable cost is the total

cost incurred for the conveyance of fuel consumption in each shipment. In

PT.XYZ, conveyance that uses fuel is only the forklifts. Below is the calculation

for fixed cost and variable cost shown in Table 4.13.

Table 4.13 Fixed Costs

Types of tools Cost type Description Cost

Forklift

Purchases with a useful life of 10 years Rp 250.000.000

Cost per month Rp 2.083.333

Cost per day Rp 90.580

Maintenance costs per year Rp 4.000.000

Maintenance fee per month Rp 333.333

Maintenance costs per day Rp 14.493

Box Trolley

Purchases with a shelf life of 3 years Rp 7.000.000

Cost per month Rp 194.444

Cost per day Rp 8.454

Maintenance costs per year Rp 1.000.000

Maintenance fee per month Rp 83.333

Maintenance costs per day Rp 3.623

Pallet

Total costs for pallets per year

(including maintenance costs) Rp 86.500

Total costs for pallets per month

(including maintenance costs) Rp 7.208

Total costs for pallets per day

(including the cost of maintenance) Rp 313

* 23 the number of working days per month including overtime

Table 4.14 Variable Cost

Fuel Distance (meters) Consumption (Liters)

SOLAR

0 - 50 0.5

51 - 80 0.75

81 - 100 1

Table 4.13 shows the cost allocation incurred in PT. XYZ for the three types of

equipments used. A fee charged is the purchasing cost in the beginning of the year

and the cost of maintenance for each month. The purchasing price used for

forklifts in PT.XYZ is Rp250,000,000 with a useful life of 10 years. The method

used is the straight line method with the assumption of no residual value at the

end of the year 10. After the calculation by adding the maintenance costs, the

values obtained for forklift, box for trolley, box for pallet, and manual box

respectively are Rp.105.386, Rp.12.077, Rp.313, and Rp.435

The fuel is used for diesel forklift. There are some assumptions based on the data

that have been obtained from the production floor and a discussion forum on the

machine: with a distance of 0-50 meters the fuel consumption is 0.5 liters, and 51-

80 meters is 0.75 liter and 81-100 meters is 1 liter. The usage of fuels impacts the

calculation of the salary. Data is further desirable that the salary calculation

supports the driver or operator per day. In this case, the amount of salary of

3,000,000 has included the allocation of costs of the employees’ health and the

facilites of the company. Below is shown a table of employees’ salary in PT.

XYZ.

Table 4.15 Salary

Type Manpower Salary per month Salary per day

Driver /

Operator

Rp

3.000.000

Rp

130.435

Supporting Man

Power

Rp

1.500.000

Rp

65.217

In Table 4.15 shows that the salary per day for driver/operator is Rp.130.435 and

Rp.65.217 for supporting man power per day. Salaries are set per month and

obtained directly from the PT. XYZ.

In Table 4.16 shows the material handling costs for its initial calculation for the

layout process in PT. XYZ. Based on the assumption of PT. XYZ, it is known that

the cost of material handling for forklift is Rp 588.00 and for trolley box is Rp

648.000 per meter.

No From To

MHE

Manpo

wer

Distance

(m)

Frec.

Existi

ng

Operating Cost Labor Cost Total

Handlin

g Cost

per Day Main

Equipme

nt

Suppor

t

Equip

ment

Fix Cost

MHC per

Day

Variable

Cost

MHC

per Day

Total

Operating

Cost per

Day

Driver /

Operato

r

Suppo

rt

Total

Labor

Cost per

Day

1

Raw

materi

al

Yung Chi Forklift Box

Manual

Driver +

Support 25,0 10

Rp

105.386

Rp

10.875

Rp

116.261

Rp

130.435

Rp

65.21

7

Rp

195.652

Rp

311.913

2 Yung

Chi Hisaka

Box

Trolley

Operato

r 15,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

3 Hisaka Murata Box

Trolley

Operato

r 19,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

4 Murata Fukuhara Forklift Box

Manual

Driver +

Support 135,0 10

Rp

117.150

Rp

58.725,0

0

Rp

175.875

Rp

130.435

Rp

65.21

7

Rp

195.652

Rp

371.527

5 Fukuh

ara Coustic Forklift

Box

Manual

Driver +

Support 158,0 10

Rp

117.150

Rp

68.730,0

0

Rp

185.880

Rp

130.435

Rp

65.21

7

Rp

195.652

Rp

381.532

6 Cousti

c Winch

Box

Trolley

Operato

r 24,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

7 Winch STR Box

Trolley

Operato

r 24,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

8 STR Stenter Box

Trolley

Operato

r 10,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

9 Stenter Finishing Box

Trolley

Operato

r 8,0 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

Table 4.16 Initial Material Handling Cost

38

No From To

MHE

Manpow

er

Distan

ce (m)

Frec.

Existi

ng

Operating Cost Labor Cost Total

Handlin

g Cost

per Day

Main

Equipme

nt

Support

Equipmen

t

Fix

Cost

OMH

per Day

Variable

Cost

OMH

per Day

Total

Operatin

g Cost

per Day

Driver /

Operator Support

Total

Labor

Cost per

Day

10 Finishi

ng

Packin

g

Box

Trolley Operator 4 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

11 Packin

g

Dept.

Baran

g Jadi

Box

Trolley Operator 20 20

Rp

12.077

Rp

12.077

Rp

130.435

Rp

130.435

Rp

142.512

39

4.2 Data Analysis

4.2.1 CRAFT Analysis Layout

The design layout and facilities at PT. XYZ in this study using CRAFT. To make

CRAFT requires extensive initial layout and flow distribution unit as the data. Both

of these data will then be processed by performing several iterations in exchange

position to produce a more efficient layout that can be seen from the total cost of

material movements by considering the feasibility of layout condition.

Alternative layout obtained from CRAFT consists of two iterations are:

1. Alternatives to exchange two departments 5 to 4

2. Alternatives to exchange two departments 3 to 1

The following is an explanation of each alternative layout is generated:

1. Exchange two departments 5 to 4

In the first iteration exchange department obtained 5 to 4 that resulted in a

decrease in material handling cost of Rp7.688.048 or 4.62% of the initial

layout.

2. Exchange two departments 3 to 1

In the second iteration gained 3 to 1 exchange department which resulted in a

decrease in material handling cost some Rp13.252.760 or 7.97%

In designing the layout of the facility by using CRAFT obtained the minimum total

cost by second iteration with a decrease of 7.97% of the existing total cost. Layout

proposed from the design by using CRAFT is as follows:

Figure 4.5 Proposed Layouts

4.2.2 Analysis of Material Transfer Fees

Designing the layout of the facility can not be separated from the transfer of material

from one department to another. This material movements certainly produce cost-

called Material Handling Cost (MHC). Material handling costs are calculated based

on the means of transport used and the cost of labor support material movements.

This study used two means of transport; forklift and trolley box.

After completing the calculation then obtained material handling cost per meter for

forklift transport equipment amounted Rp 588,00 and for conveyance of Rp648,00

permeter trolley box. Calculation of the costs of moving the material is obtained from

the multiplication of the frequency that occurs with the distance between the facility

and the cost of material movements by means of transport used. Table 4.17 shows the

comparison material handling costs .

Table 4.17 Comparison Material Handling Cost

Layout Material Handling Cost Efficiency

Layout Existing Rp166.217.184 0%

Layout CRAFT iteration 1 Rp158.529.136 4.62%

Layout CRAFT iteration 2 Rp152.963.424 7.97%

At table 4.17 can be seen by comparing the total cost of material handling in the

production floor PT. XYZ. In the first iteration, the material handling cost existing

layout reduced as much as Rp7.688.048 and the second iteration reduced the material

handling cost with a difference of Rp13.252.760.

4.2.3 Analysis of Machine Requirement

The design of facility layout certainly consider several factors to get the optimal

layout, including the needs of the machine. Machine needs is very closely related to

the machine capacity. Therefore, the calculation of the needs of the machine has

previously been described in the routing sheet in Table 4.18. Table 4.18 is a

comparison table between machine required with existing machine.

Tabel 4.18 Comparison Engines

Machine

Number of

Existing

Machine

Total

Requirements

Machine

Yung Chi 7 9

Hisaka 9 14

Murata 2 9

Fukuhara 42 53

Coustic 1 2

Winch 7 3

STR 1 4

Stenter 2 3

Based on table 4.18, resulted the need of the machine to produce knitted fabric in

PT.XYZ. The explanation of the number and types of machines used is provided

below.

1. Yung Chi machine

This machine is used for winding yarn on cones to cheese. In the existing

condition of the company has 7 machines Yung Chi. After calculating the

needs of the machine, the company requires 9 machine Yung Chi, so the

company needs to add a number of new machines to improve the

effectiveness of the company's production. The addition of 2 machines in this

activity is to maximize the output of this process, since the engine capacity

Yung Chi is not too large, so if the company adds to the engine in this process

will increase the effectiveness of the company's production.

2. Hisaka machine

These machines are used in the dyeing process yarn are inserted into the tube

dyeing. The machine consists of two types, ie for dyeing and drying. In the

present conditions, the company has 7 dyeing machines and 2 drying

machines. Both types of machines integrated with each other. After

performing the calculation engine requirements, companies need to add 2

dyeing machines and 3 drying machines. The turn around time on this

machine long enough so that the required additional machinery to reduce the

queue to be included in the activity of this machine.

3. Murata machine

Machine is a machine used for winding yarn from the cheese to the cones.

The company has only 2 current machine, while the company needs to require

a total of 9 Murata machines. At this workstation, the amount of material that

goes quite a lot, so it takes more machines to prevent material build up.

4. Fukuhara machine

The process that occurs on this machine is a knitting process that produces

some kind of fabric using yarn materials. In this machine, the production

process took quite a long time, and so it requires a considerable amount of

machines that are balancing material during on going production. From the

calculations made to their engines, the company needs to add 11 machines

from the initial number of 42 machines.

5. Coustic machine

In this machine, a process that occurs is the administration of drugs on the

fabrics that have gone through the process so that the color knit fabric more

concentrated. Currently, the company only has one Coustic machine, whereas

after calculation in conducting this process takes 2 Coustic machines.

Therefore, the addition of a number of the machine unit by the company is

needed to improve the effectiveness of this process and reduce the buildup of

material, given that output in the previous process amounts to quite a lot, so

that the material to be processed on coustic machine is also a large amount.

6. Winch machine

This machine is a machine to perform the rinsing process to remove the stain,

wax and the remainder of the drug at the time of finished knitted fabric. The

Company has 7 Winch machine so the engine has exceeded demand in

producing knitted fabrics. Excess amounts of these machines can be used by

companies to accept the creation of other products that use a winch machine

in the production process

7. STR machine

The process that takes place in this machine is a maturation process to harden

and smooth out the fabric. The Company has one STR machine, while the

machine needs STR is number 4. Therefore, companies need to increase

machine three units to reduce the waiting time material and to increase

production of the company.

8. Stenter machine

Stenter machine is a machine that is responsible for managing shrinkage

diameter and gramasi fabric. This machine is the latest machine used in

producing knitted fabrics. The company has had 2 machine stenter and

calculation engine requirements, companies need to add one more unit of the

machine in order to track the production and balance can be optimally and

effectively.

4.2.4 Analysis Space Needs and Distance

After conducting an analysis of the needs of the engine, the design of the new layout

analysis space requirements. the area required by each of the existing facilities in the

activities of production, including the dimensions of the machine or the following

facilities with the amount of the allowance granted to the operator, alleys, and

material. In an analysis of this space needs to do a comparison between the area of

space used on the layout of existing companies with the area used for the proposed

layout. In table 4.19 show a comparison existing distance with the proposed. Table

4.20 viewable area ratio of each machine or activity PT.XYZ overall production floor

Table 4.19 Distance

No Facilities Existing Area (m2)

Proposed Layout

(m2)

1 Raw material - Yung

Chi 27 32.67

2 Yung Chi - Hisaka 4.75 25.47

3 Hisaka - Murata 7.5 26.55

4 Murata - Fukuhara 43.75 33.08

5 Fukuhara - Coustic 45 27.33

6 Coustic - Winch 12 1.75

Table 4.19 Distance (cont’d)

7 Winch - STR 12 21.25

8 STR - Stenter 15.5 21.8

9 Stenter - Finishing 6 6.87

10 Finishing - Packaging 6.5 4.46

11 Packaging – Finished

good 25 29.2

Total area 205 230.43

Based on the table 4:19 to an increase in the total distance between the midpoint of

each department on the proposed layout around 25m. The increase in the distance

between the mid-point for adjusting the shape of each department to avoid the

occurrence of backtracking.

Table 4.20 Comparison of Space Needs

No Facilities Existing Area

(m2)

Total Area Needed

(m2)

1 Raw material 1863 1863

2 Yung Chi 360 360

3 Hisaka 645 810

4 Murata 322.5 322.5

5 Fukuhara 2323 2323

6 Coustic 540 540

7 Winch 1290 645

8 STR 540 1020

9 Stenter 612 612

10 Finishing 408 408

11 Packaging 720 720

12 Finished goods 1725 1725

Total area 11348,5 11348,5

Based on Table 4.20 it can be seen that there are some facilities to undergo extensive

changes in the area. But overall, the area needed for the production process on the

proposed layout the same as the area used on the layout of existing companies. Here

is an analysis of the facilities that undergo extensive changes in the area of the

proposed layout.

1. Yung Chi machine

Yung Chi Machine does not change the area but there is a change in the

composition of the machine into a vertical, horizontal form. This change was

made to make allowances for the flow of material and labor. Size and position

of the new engine is now very comfortable with the working conditions for

the activities in this machine are traversed by raw material for these types of

knitted fabrics.

2. Hisaka machine

Hisaka machine changing area and change the layout. The initial position

hisaka machine are horizontal to vertical. In the layout of the existing

company, this facility requires extensive area of 645m2. Meanwhile, after

making adjustments and calculation engine needs at this facility by an

additional amount of 5 pieces and machine need a total area of 810m2.

Comprehensive change was also based on allowance for workers passing to

ensure there is no buildup of the current thread will go to the dyeing process.

3. Murata machine

Murata Machine does not change significantly due to a large enough area

considered to be ideal for a number of existing machine. In addition, the area

on the machine Murata considered quite convenient for the allowance for

materials and workers so that there should be no additional area and change

the position of machine.

4. Fukuhara machine

On the machine Fukuhara, do not change, because the area of the machine

Fukuhara quite extensive and is considered capable of accommodating the

existing material. In addition, the machine are still many alleys for allowances

for workers and stacks of material to be processed.

5. Coustic machine

Coustic machine does not change the area but there is a change in the

composition of the machine into a vertical, horizontal form due to the addition

of machine, so that the position of the machine is set so that materials and

workers comfortable with working conditions in this facility. The layout of

machine Coustic also be adjacent to machine because the process flow

Fukuhara two machines are very tight linkages.

6. Winch machine

Winch machines undergo extensive changes in the area but did not change the

shape of the existing layout. On the machine there is a reduction Winch area

is needed, of 1290m2 into 645m2. This happens because after the calculation

needs of the machine, the number of machines required only amounted to 3

units and not too many activities checking the products by the operator of the

area's vast perceived to be quite effective when scaled.

7. STR machine

In the machine area STR changes but the position of the engine as the existing

layout. The area required STR machine turns into 1020m2 of 540m2. The

addition of this area will increase the allowance for operators thereby

increasing operator comfort in work.

8. Stenter machine

Stenter machines experiencing a change in the layout engine placement.

machine turned into vertical position. The area of the machine is already

considered to be loose enough to traffic and workers in charge of the area for

the material being processed in this machine.

4.2.5 Analysis of Result

(a) Current Layout

(b)Proposed Layout

Figure 4.6 Comparison Layouts

It can be seen from the figure 4.6 there is a difference between the initial layout flow

processes with the proposed layout. The initial layout process flow is irregular

because there are a lot of backtracking and crashes marked with red dots.

Backtracking contained in Murata machine to Fukuhara machine, Fukuhara to

Coustic and Coustic to STR, and on proposed layout can be seen the flow process at

the proposed layout which has no backtracking and crashes.

Table 4.20 Calculation Material Handling Cost

Table 4.20 describes total Material Handling Cost on real condition by using the

actual distance with a total of Rp 79,968,240 at initial layout. The material handling

cost proposed layout decreased by 7.97% from the material handling cost initial

layout. So can be conclude the proposed layout better than the initial layout which

has material handling cost Rp 73.594.771.

No Machine Distanc

e

(meter)

frequency

transfer

Transfer

cost MHC

From To

1 Raw

material Yung Chi 25 230 588 3.381.000

2 Yung Chi Hisaka 15 460 648 4.471.200

3 Hisaka Murata 19 460 648 5.663.520

4 Murata Fukuhara 135 230 588 18.257.400

5 Fukuhara Coustic 158 230 588 21.367.920

6 Caustic Winch 24 460 648 7.153.920

7 Winch STR 24 460 648 7.153.920

8 STR Stenter 10 460 648 2.980.800

9 Stenter Finishing 8 460 648 2.384.640

10 Finishing Packaging 4 460 648 1.192.320

11 Packaging Finished

goods 20 460 648 5.961.600

Total 79.968.240

CHAPTER V

CONCLUSION AND RECOMMENDATIONS

1.1 Conclusion

Based on the research that has been done, it can be concluded that the purpose

of this research has been reached. Designing the proposed layout of the

facility is able to minimize material handling costs at production floor of

PT.XYZ. CRAFT second iteration is more efficient than CRAFT first

iteration in material handling cost. It can be seen from the total cost by using

CRAFT second iteration is Rp152.963.424. Reduce 7.97% by material

handling cost proposed layout compare with the initial layout.

1.2 Recommendation

For further research, the analysis can use another method to compare which

method that has the best result in reducing the material handling cost.

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Heragu, Sundereesh. Facilities Design. PWS Publishing Company. (1997)

Tompkins, J.A., White, J.A & Bozer, Y.A. Facilities Planning. John Wiley & Sons,

Inc (2010).

Wignjosoebroto, Sritomo. Tata Letak Pabrik dan Pemindahan Bahan. Gunawidya.

(2000).