2. Pengantar Perencanaan Tata - Letak D0052 Pengantar Sistem dan Teknik Industri Universitas Bina Nusantara Revised 2002

3. Brief History of Plant Layout Perusahaan – perusahaan masa lalu menggunakan tenaga ‘draftsperson’ untuk melengkapi tata letak pabrik. The general belief was that there was a void of expertise in facility layout design. Problems could be overcome with an extra forklift or conveyor length.

4. Plant Layout Raw Stock QC Rec Ship Shear Screw Machine QC Stamp Assembly Brake Mill Lathe Weld Finish Grind Parts Stock Drill

5. Impact of Poor Plant Layout Tingginya biaya ‘material handling’. Keterlambatan siklus waktu dan ‘lead time’. Persediaan WIP tinggi Mutu rendah. Kerusakan produk. Masalah keamanan dan moral. Utilitas peralatan rendah. Congested aisles Ruang yang tidak digunakan.

6. Bagaimana memperbaikinya? Lean Manufacturing dan Cellular Flow 6 Assemblers Batch Assembly C/T 4.5 days Sebelum:

7. How Can We Improve? Lean Manufacturing dan Cellular Flow 6 Assemblers Flow / Pull C/T 53 minutes Sesudah :

8. Facility Improvement Pitfalls Poorly planned layout Lack of employee involvement Lack of management commitment Budgetary constraints leading to a “piecemeal” approach Focus on the almighty ROI versus the future of the business Short term management focus

9. Manufacturing Savings Where can we save costs in manufacturing? Reduce or Eliminate- Work-in-process inventories (WIP) Non-value added activities Material handling costs Processing time Product defects

10. Manufacturing Savings The largest components of factory labor and the cost of materials purchased and used in a factory are: Internal transportation costs Material handling costs Storage costs This includes both our manufacturing plants and those of our suppliers!

11. Facilities Layout Goals Goals should include: –Minimize unit cost. Minimize project cost. –Optimize quality. –Promote the effective use of (a) people, (b) space, (c) equipment, and (d) energy. –Provide for (a) employee convenience, (b) employee safety, and (c) employee comfort. –Control project cost. –Achieve the production start date. –Build flexibility into the plan. –Reduce or eliminate excessive inventory. –Achieve miscellaneous goals.

12. Five Types of Facility Design Projects 1. New Facility – fewer restrictions and constraints on the layout since it is new 2. New Product – integration of a new product into the existing process and layout 3. Design Changes – incorporate the impact of design changes into the manufacturing process 4. Cost Reduction – redesign the existing layout to facilitate cost reduction programs and ideas 5. Retrofit – similar to a new facility layout except with the constraints present

13. Cycle Times and Materials Handling Old Adage: “the smaller the lot size, the higher the materials handling and setup costs” “the faster the assembly line conveyor speed, the higher the production output” Response: Ask the right answer and get the right question... Focus on the true problems that prevent smaller lot sizes and faster production speeds.

14. Cycle Times and Materials Handling Getting the right answer to the right question... 30 in. Typical Speed = 60 in. / 18 sec = 200 in. / min Range width 30 in. Units / shift: 60 sec / cycle time per unit = 60 / 18 = 3.33 units per minute 3.33 units per minute X 60 minutes X 7 hours = 1400 units / shift

15. Cycle Times and Materials Handling Getting the right answer to the right question... 12 in. Typical Speed = 42 in. / 15 sec = 168 in. / min Range width 30 in. Units / shift: 60 sec / cycle time per unit = 60 / 15 = 4 units per minute 4 units per minute X 60 minutes X 7 hours = 1680 units / shift

16. Cycle Times and Materials Handling The right question was how to increasing production while reducing cycle time...the wrong answer was speeding up the line! Results: 1,680 / 1,400 = 1.2 = 20% Production Increase

17. Materials Handling Materials handling is a non-value activity that your customer is unwilling to pay for. Constantly question material handling methods and manufacturing methods... your competitors do! Just because you “have always done it that way” does not make it right.

18. Materials Handling Mistakes WAREHOUSE A Local Company’s Materials Handling Process- Step 1- Begin Assemblies Step 2- Move to WIP Warehouse Step 3- Store in WIP Warehouse Step 4- Move back to Manufacturing

19. Materials Handling Mistakes WAREHOUSE Local Company’s Materials Handling Process- Step 5- Begin Assembly Continue Until Complete 36 Trailers / Day Step 6- Back to the Warehouse

20. Materials Handling Mistakes Material was handled so much that damage was inevitable. Their customer began penalizing them $100 per damaged part received due to the poor finished goods quality. The materials handling inefficiencies manifested themselves in higher product costs, larger amounts of WIP, poor product quality and longer lead times. The parts were inspected eight (8) times on average, product yield was a dismal 60%. A reduction in two (2) inspections steps generated over $1M in annual savings...the right question should have been “Why are we moving these parts so much?” Company Results:

21. Materials Handling Example Fabric Rolls in Excess of 100# Electric Lift Hoist

22. Key Manufacturing Fundamentals Four Fundamental Customer Expectations: 1.Product Quality 2.Delivery as scheduled / requested 3.Flexibility to handle change and service 4.Low $$$ One method to achieve this is by implementing Lean Manufacturing principles

23. Benefits of Lean Lead Time Reduction 0255075100 Percentage of Benefits Achieved Productivity Increase WIP Reduction Quality Improvement Space Utilization