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Tata Letak Fasilitas

Bab 9-10. Tata Letak Fasilitas. Penjadwalan. Menentukan kapan tenaga kerja , peralatan , fasilitas yang diperlukan untuk menghasilkan suatu produk atau memberikan layanan Tahap terakhir dari perencanaan sebelum produksi terjadi. Tujuan Fasilitas Tata Letak.

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Tata Letak Fasilitas

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  1. Bab 9-10 Tata LetakFasilitas

  2. Penjadwalan • Menentukankapantenagakerja, peralatan, fasilitas yang diperlukanuntukmenghasilkansuatuprodukataumemberikanlayanan • Tahapterakhirdariperencanaansebelumproduksiterjadi

  3. Tujuan Fasilitas Tata Letak • Meminimalkanbiayapenanganan material • Memanfaatkanruangsecaraefisien • Memanfaatkantenagakerjasecaraefisien • menghilangkanhambatan • Memfasilitasikomunikasidaninteraksiantarapekerja , antarapekerjadan supervisor mereka , atauantarapekerjadanpelanggan • Reduce manufacturing cycle time or customer service time

  4. Tujuan Fasilitas Tata Letak • Menghilangkan limbah yang berlebihan • Memfasilitasi masuk, keluar , dan penempatan material, produk , atau orang-orang • menggambungkan ukuran keselamatan dan keamanan • Mempromosikan produk dan layanan berkualita • Mendorong kegiatan perawatan yang tepat • Memberikan kontrol visual operasi atau kegiatan • Memberikan fleksibilitas untuk beradaptasi dengan perubahan kondisi Meningkatkan kapasitas

  5. Jenis dasar Layouts • Process Layout • Mesin dikelompokkan berdasarkan proses yang mereka lakukan • Product Layout • Susunan linear dari workstation untuk menghasilkan produk tertentu • Fixed Position Layout • Digunakan dalam proyek di mana produk tersebut tidak dapat dipindahkan

  6. Women’s lingerie Shoes Housewares Cosmetics and jewelry Children’s department Women’s dresses Women’s sportswear Entry and display area Men’s department Process Layout pada Jasa Figure 5.1

  7. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly Manufacturing Process Layout Figure 5.2

  8. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly Manufacturing Process Layout Figure 5.2

  9. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly Manufacturing Process Layout Figure 5.2

  10. In Out A Product Layout Figure 5.3

  11. PRODUCT LAYOUT PROCESS LAYOUT Comparison Of Product And Process Layouts 1. Description Sequential arrangement Functional grouping of machines of machines 2. Type of Process Continuous, mass Intermittent, job shop production, mainly batch production, assembly mainly fabrication 3. Product Standardized Varied, made to stock made to order 4. Demand Stable Fluctuating 5. Volume High Low 6. Equipment Special purpose General purpose 7. Workers Limited skills Varied skills Table 5.1

  12. PRODUCT LAYOUT PROCESS LAYOUT Comparison Of Product And Process Layouts 8. Inventory Low in-process, High in-process, high finished goods low finished goods 9. Storage space Small Large 10. Material Fixed path Variable path handling (conveyor) (forklift) 11. Aisles Narrow Wide 12. Scheduling Part of balancing Dynamic 13. Layout decision Line balancing Machine location 14. Goal Equalize work at Minimize material each station handling cost 15. Advantage Efficiency Flexibility Table 5.1

  13. Fixed-Position Layouts • Tipeproyek • Peralatan , pekerja , bahan , sumberinformasilainnyadibawakesitus • TingginyaTenagakerjaterampil • SeringrendahtetapBiaya • Tipebiayavariabelbiasanyatinggi

  14. Designing Process Layouts • Meminimalkan biaya material handling • Blok Diagram • Minimize nonadjacent loads Minimalkan beban nonadjacent • Gunakan ketika data kuantitatif yang tersedia avalaibel • hubungan Diagram • Berdasarkan preferensi lokasi antara area • Gunakan ketika data kuantitatif tidak available

  15. Load Summary Chart FROM/TO DEPARTMENT Department 1 2 3 4 5 1 — 100 50 2 — 200 50 3 60 — 40 50 4 100 — 60 5 50 — Composite Movements Composite Movements 2  3 200 loads 3  5 50 loads 2  4 150 loads 2  5 50 loads 1  3 110 loads 3  4 40 loads 1  2 100 loads 1  4 0 loads 4  5 60 loads 1  5 0 loads Process Layout Example 5.1

  16. Load Summary Chart 2 1 FROM/TO DEPARTMENT 3 Department 1 2 3 4 5 1 — 100 50 2 — 200 50 3 60 — 40 50 4 100 — 60 5 50 — 4 5 Composite Movements Composite Movements 2  3 200 loads 3  5 50 loads 2  4 150 loads 2  5 50 loads 1  3 110 loads 3  4 40 loads 1  2 100 loads 1  4 0 loads 4  5 60 loads 1  5 0 loads Process Layout Example 5.1

  17. 110 Load Summary Chart 100 200 2 1 FROM/TO DEPARTMENT 150 50 3 50 Department 1 2 3 4 5 60 1 — 100 50 2 — 200 50 3 60 — 40 50 4 100 — 60 5 50 — 4 5 40 Composite Movements Composite Movements 2  3 200 loads 3  5 50 loads 2  4 150 loads 2  5 50 loads 1  3 110 loads 3  4 40 loads 1  2 100 loads 1  4 0 loads 4  5 60 loads 1  5 0 loads Grid 1 Process Layout Example 5.1

  18. Load Summary Chart 150 100 2 1 FROM/TO DEPARTMENT 200 50 40 3 60 Department 1 2 3 4 5 110 50 1 — 100 50 2 — 200 50 3 60 — 40 50 4 100 — 60 5 50 — 4 5 Composite Movements Composite Movements 2  3 200 loads 3  5 50 loads 2  4 150 loads 2  5 50 loads 1  3 110 loads 3  4 40 loads 1  2 100 loads 1  4 0 loads 4  5 60 loads 1  5 0 loads Grid 2 Process Layout Example 5.1

  19. Computerized Layout Solutions • CRAFT - block diagramming • CORELAP - relationship diagramming • Simulation

  20. Service Layouts • Usually process layouts due to customers needs • Minimize flow of customers or paperwork • Retailing tries to maximize customer exposure to products • Computer programs consider shelf space, demand, profitability • Layouts must be aesthetically pleasing

  21. Designing Product Layouts • Product layouts or assembly lines • Develop precedence diagram of tasks • Jobs divided into work elements • Assign work elements to workstations • Try to balance the amount work of each workstation

  22. Line Balancing • Precedence diagram • Network showing order of tasks and restrictions on their performance • Cycle time • Maximum time product spends at any one workstation

  23. production time available desired units of output Cd = (8 hours x 60 minutes / hour) (120 units) Cd = 480 120 Cd= = 4 minutes Line Balancing • Precedence diagram • Network showing order of tasks and restrictions on their performance • Cycle time • Maximum time product spends at any one workstation Cycle time example

  24. Flow Time vs Cycle Time • Cycle time = max time spent at any station • Flow time = time to complete all stations

  25. 1 2 3 4 minutes 4 minutes 4 minutes Flow Time vs Cycle Time • Cycle time = max time spent at any station • Flow time = time to complete all stations Flow time = 4 + 4 + 4 = 12 minutes Cycle time = max (4, 4, 4) = 4 minutes

  26. Minimum number of workstations Efficiency i i= 1 i i= 1   ti ti N = E = nCa Cd Efficiency of Line where ti = completion time for element i j = number of work elements n = actual number of workstations Ca = actual cycle time Cd = desired cycle time

  27. Line Balancing Process 1. Draw and label a precedence diagram. 2. Calculate the desired cycle time required for the line. 3. Calculate the theoretical minimum number of workstations. 4. Group elements into workstations, recognizing cycle time and precedence constraints. 5. Calculate the efficiency of the line. 6. Stop if theoretical minimum number of workstations on an acceptable efficiency level reached. If not, go back to step 4.

  28. Line Balancing

  29. WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit — 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 Line Balancing Example 5.2

  30. WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit — 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Example 5.2

  31. WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit — 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 0.2 0.1 + 0.2 + 0.3 + 0.4 0.4 B 2400 6000 40 hours x 60 minutes / hour 6,000 units Cd = = = 0.4 minute A 0.3 0.1 D 1.0 0.4 N = = = 2.5 workstations C 0.4 Line Balancing Example 5.2

  32. WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit — 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 0.2 0.1 + 0.2 + 0.3 + 0.4 0.4 B 2400 6000 40 hours x 60 minutes / hour 6,000 units Cd = = = 0.4 minute A 0.3 0.1 D 1.0 0.4 N = = = 2.5 workstations C 0.4 Line Balancing 3 workstations Example 5.2

  33. WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit — 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  34. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  35. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  36. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  37. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  38. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D 3 D 0.1 none 0.2 B A 0.3 0.1 D C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  39. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS Work station 1 Work station 2 Work station 3 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D 3 D 0.1 none 0.3 minute 0.4 minute 0.3 minute 0.2 B A, B A 0.3 0.1 D D C C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

  40. REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS Work station 1 Work station 2 Work station 3 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D 3 D 0.1 none 0.3 minute 0.4 minute 0.3 minute 0.2 0.1 + 0.2 + 0.3 + 0.4 3(0.4) B A, B 1.0 1.2 A 0.3 0.1 D E = = = 0.833 = 83.3% D C C 0.4 Line Balancing Cd = 0.4 N = 2.5 Example 5.2

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