Relayout Fasilitas Produksi Dengan Metode Systematic Layout Planning dan ALDEP

Abstract

PT XYZ is one of the largest manufacturing companies in Indonesia operating in the garment industry, with 13 manufacturing facilities and subsidiaries spread across various regions in the country. The main issue faced by PT XYZ is the misalignment between the placement of production facilities and the flow of the production process. This results in backtrack and increased material movement distance between workstations. The total rectilinear distance of material movement per month is recorded at 507,953.6 meters. Consequently, the time required for material transfer becomes relatively long, which increases the material handling cost incurred by the company. In one working month (22 days), the company spends approximately Rp. 136,665,400.00 on material handling. This study aims to propose an improved production layout at PT XYZ in order to minimize material movement distance, eliminate backtrack, and reduce material handling costs. The layout improvement process is conducted using the Systematic Layout Planning (SLP) and Automated Layout Design Program (ALDEP) methods. The results of the study show that the optimal proposed layout is obtained through the SLP method. In addition to providing significant cost savings, the layout ensures a smooth material flow without any backflow, including both backtrack and reverse flow. Based on the calculation of the proposed layout, the material handling cost is reduced to Rp. 53,288,188.25 per month, with a total inter-department distance of 969.2 meters and a monthly material handling path length of 200,637.8 meters. This leads to a cost reduction of Rp. 83,377,211.75 or an efficiency improvement of 61%.