Mata Kuliah: Tata etak Fasilitas (TKI 4215) FOW, SPACE, AND ACTIVITY REATIONSHIP
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 ocation restrictions for departments, if any Adjacency requirements between pairs of departments, if any
FOW 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 ine atau pola aliran lurus ( I Flow) O-1 O-2 O-3 O-4 O-5 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
Flow Between Departments: Serpentine atau zig-zag (S Flow) O-1 O-2 O-1 O-4 O-5 O-4 O-3 O-2 O-3 O-6 O-5 O-6 (A) (B) Pola aliran seperti huruf S diatas sangat baik diterapkan bilamana aliran proses produksi lebih panjang dibandingkan dengan panjang area yang tersedia. Untuk itu aliran bahan dibelokkan untuk mengurangi panjangnya garis aliran yang ada.
Flow Between Departments: Pola aliran menyerupai huruf U (U Flow) O-6 O-5 O-4 O-1 O-2 O-3 Pola aliran ini dipakai bilamana dikehendaki akhir dari proses produksi akan berada pada lokasi yang sama dengan awal proses produksi. Hal ini meningkatkan pemanfaatan fasilitas transportasi dan mudah untuk mengawasi keluar masuknya material dan produk jadi. Aliran perpindahan bahan relatif panjang.
Flow Between Departments: Circular (O Flow) O-3 O-2 O-4 O-1 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.
Flow Between Departments: ODD angle O-2 O-1 O-3 O-4 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 O-5
POA AIRAN MENURUT KEUAR-MASUK BAHAN AT THE SAME OCATION AT THE SAME OCATION ON ADJACENT SIDES ON ADJACENT SIDES
POA AIRAN MENURUT KEUAR-MASUK BAHAN ON THE SAME SIDE BUT AT OPPOSITE ENDS ON THE SAME SIDE BUT AT OPPOSITE ENDS ON OPPOSITE SIDES ON OPPOSITE SIDES
MACAM POA AIRAN YANG BERSIANGAN A B C D E F G H UNINTERRUPTED FOW PATHS A F C H E B D G INTERRUPTED FOW PATHS
POA AIRAN BAHAN UNTUK PROSES PERAKITAN (ASSEMBY)
Pola aliran bahan untuk proses perakitan: Combination Assembly ine Patern 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: Tree Assembly ine / Spine Flow Patern Sub-assembly line akan berada pada kedua sisi dari aliran main assembly. Biasanya pada penerapan pola aliran ini, main assembly akan berada ditengah bagian pabrik.
Pola aliran bahan untuk proses perakitan: Dendretic Assembly ine Patern 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.
Pola aliran bahan untuk proses perakitan: Overhead Assembly ine Patern 2nd Floor 1st Floor Pola aliran ini merupakan model pola aliran untuk lantai produksi yang lebih dari satu lantai.
Types of Departments/ayouts Volume High Product Department Medium Product ayout Fixed ocation ayout Fixed Materials ocation Department Product Family Department Group Technology ayout Process ayout Process Department ow ow Medium High Variety Source: John S. Usher class notes
Five types of layout Product layout Process layout Fixed-position layout Group-technology layout Hybrid layout
Product layout
Product ayouts Product A Department D D M G P D A Receiving Department Product B Department M M Product C Department D G P A Shipping Department G G P A Source: John S. Usher class notes
Process layout TM TM DM DM TM TM DM VMM VMM BM BM
The Process ayout athe Department Milling Department M M Drilling Department D D D D M M D D D D G G G P G G Grinding Department Receiving and Shipping G P Painting Department A A A Assembly Source: John S. Usher class notes
Flow of Materials in Process ayouts athe Department Milling Department M M Drilling Department D D D D M M D D D D G G G P G G Grinding Department Receiving and Shipping G P Painting Department A A A Assembly Source: Russell & Taylor, 2007
Group technology layout TM DM VMM DM BM TM TM BM VMM DM TM
Product Family (Cellular) ayout G G Rotational Parts Cell D P M M M D D G G P D D D D G A M Rectangular Parts Cell A G Special Department Receiving and Shipping Source: John S. Usher class notes
Direction of part movement within cell A Manufacturing Cell HM VM Paths of three workers moving within cell Worker 3 VM Material movement Key: S = Saw = athe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder Worker 2 G Final inspection S In Source: John S. Usher class notes Worker 1 Finished part Out
Project (Fixed-Position) ayout G G D D D G Storage M P A A G Storage Receiving and Shipping Source: John S. Usher class notes
Hybrid layout TM TM VMM BM TM TM DM
Hybrid ayouts 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 DM TM TM BM TM TM
General Characteristics Characteristic Product Process Product Family Project Throughput Time ow High ow Medium Work in process ow High ow Medium Skill evel Choice High Med-High Mixed Product Flexibility ow High Med-High High Demand Flexibility Medium High Medium Medium Mach Utilization High Med-ow Medium-High Medium Worker Utilization High High High Medium Reliability Can be low High High Medium Unit production cost ow High ow High
Exercise What Type of ayout? Ford ouisville Assembly Plant Suburban Hospital ouisville International Airport KFC Restaurant Boeing Aircraft
Automated Manufacturing Cell Source: John S. Usher class notes
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 adder layout two machines work on same part Open field layout most complex
PAINTING MEJA PERAKITAN PENGEMASAN PENYIMPANAN AAT PENERIMAAN 1 2 3 4 6 5 11 12 8 8 7 Flow diagram MESIN FRAIS 1 MESIN BUBUT 2 Peluncur Bahan 1 3 MEJA MEJA 6 Peluncur Bahan 6 MESIN BOR 3 5 MESIN BOR 2 3 7 Peluncur Bahan PEMANGGANG Peluncur Bahan 4 Peluncur Bahan Peluncur Bahan 59 Peluncur Bahan Peluncur Bahan 13 14 10 9 20 18 12 11 13 PENGIRIMAN GUDANG DIAGRAM AIR (FOW DIAGRAM) ASSEMBING 7 FINISHING 16 17 15 8 18 6 Peluncur Bahan
FOW PANNING
Flow planning hierarchy
Flow Measurement
A. STRING DIAGRAM String Diagram merupakan alat untuk menggambarkan aliran bahan/material dalam layout, dengan menggunakan tali, benang, kawat, dan sebagainya. OTahapan pembuatan : Tusukkan paku, baut atau jarum pentul pada fasilitasfasilitas 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
PENGOAHAN IMBAH 6 W/H FINISH GOOD 1 3 7 12 13 10 11 2 4 5 W/H MATERIA 8 9 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
ANGKAH PENYEESAIAN O Kumpulkan data Volume of Handling, luas area/departemen & alur proses produksi tiap produk PRODUK VOUME OF HANDING % VOUME OF HANDING AUR 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
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 TO A A B C D E F G H I B 20 5 C 20+20+ 5 20 5 25+2 0 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 Perpindahan P1 dari A ke B Sebesar 20 H 5 25 20+5+5 I 25 20+20+5 20+5+ 5
KONDISI AWA FROM TO A B C D E F G H J 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
Volume Aliran Dari Jarak FORWARD Diagonal Jarak dari Koefisien diagonal Moment Jarak Moment (20+20+65+20+25+50+30+ 30) = 260 (260 x 1) = 260 1 (10 x 1) =10 BACKWARD Jarak dari diagonal (5+5) =10 (45+20+20+45) =130 (30+45+5+25+25) =130 (130 x 2) = 260 2 (70 x 2) =140 (45+25) =70 (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.
Kondisi setelah perubahan aliran A-B-D-E-F-H-I FROM TO A A B C D E F G H I B 20+25 5 20 C 20+20+ 5 20 5 D 5 25 E 5 20 F 5 20 20+20+20 +5 5 20+2 5 20+5+2 5 G 5 20 20+20+5+ 5 H 5 25 20+5+5 I 20+20+ 5 20+5+5+2 5
KONDISI PERBAIKAN FROM TO A B C D E F G H I 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
Volume Aliran Dari Jarak Jarak dari diagonal FRWD Diagonal Moment Koefisien Jarak Jarak dari diagonal BCWD 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 REATIONSHIP CHART Teknik kualitatif yang sederhana dalam merencanakan tata letak fasilitas atau mesin. Berdasarkan derajat hubungan aktivitas dari masing-masing fasilitas atau mesin tersebut. 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
Kode Derajat Hubungan Antar Fasilitas Value A Closeness Absolutely necessary ine code Numerical weights 16 E I O U X Especially important Important Ordinary closeness OK Unimportant Undesirable 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 O E O I O O O U O X Red Orange or Yellow Green Blue Uncolored Brown
1 2 3 ACTIVITY REATION FASIITAS A FASIITAS B FASIITAS C CHART I 1 X 2 Derajat hubungan O 3 Alasan kedekatan hubungan
Contoh Alasan Kedekatan KODE AASAN Hubungan DESKRIPSI AASAN 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 U I CNC Machine (10 x 25) Punch Press 2 (15 x 15) Vertical Turret athe (10 x 10) athe (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 1 4 9 2 2 3 4 4 8 2 7 7 2 2 4 3 5 7 4 6 8 9 3 6 9 1 7 3 6 5 2 9 5 1 5 3 3 5 5 5 7 ACTIVITY REATIONSHIP 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
Space Requirements 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 ess inventories (using a pulled system) Manufacturing cells Companies are downsizing
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 etak Pabrik dan Pemindahan Bahan. Surabaya: Guna Widya.