Proposed Improvement In The Layout Of The Production Floor Using The Group Technology Layout And Corelap Algorithm On CV. The New Era Of The Panel

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Proposed Improvement in the Layout of the Production Floor using Group Technology Layout and Corelap Algorithm on CV. The New Era of the Panel

Introduction

In today's fast-paced manufacturing industry, efficiency and productivity are crucial for companies to stay competitive. CV. The new era of the panel, a manufacturing company engaged in processing iron plates into various product components, is no exception. However, the company faces significant challenges in fulfilling consumer orders on time due to an inefficient layout of production floors. This problem arises due to unnecessary movements, such as backtracking and cross movements, as well as a distance that is too far between the production station. To overcome these problems, it is essential to improve the layout of the production floor by utilizing the Group Technology Layout (GTL) method and the Corelap algorithm.

The Problem of Inefficient Production Floor Layout

The production floor layout of CV. The new era of the panel is a complex system that involves various production stations, material handling, and worker movements. However, the current layout is inefficient, resulting in unnecessary movements, such as backtracking and cross movements, which increase the total movement and cost of handling material. This inefficiency not only affects the production process but also leads to increased operational costs and decreased customer satisfaction.

The Group Technology Layout (GTL) Method

The Group Technology Layout (GTL) method is a layout design approach that aims to group similar production stations together to minimize unnecessary movements and reduce the total movement and cost of handling material. This method involves analyzing the production process, identifying the production stations, and grouping them based on their similarity. The GTL method has been widely used in various manufacturing industries to improve production efficiency and reduce operational costs.

The Corelap Algorithm

The Corelap algorithm is a computer-based algorithm that is used to optimize the layout of production floors. This algorithm uses a mathematical model to analyze the production process, identify the production stations, and determine the optimal layout that minimizes unnecessary movements and reduces the total movement and cost of handling material. The Corelap algorithm has been widely used in various manufacturing industries to improve production efficiency and reduce operational costs.

Analysis of Improvement of Production Floor Layout

The results of the study showed a significant decrease in total movement on the production floor. Before repairs, the total movement was recorded at 112,094 m/month, which then declined to 89,390 m/month with the application of the Group Technology Layout. Meanwhile, the use of Corelap algorithm also shows positive results with a total movement reaching 100,114 m/month. Reduction of this movement contributes to better production efficiency.

In addition, the cost of handling material on the production floor has decreased from Rp 22,418,800/month to Rp 17,878,000/month using the Group Technology Layout. This cost also decreased to Rp 22,022,800/month with the application of Corelap algorithm. By comparing the total movement and cost of handling material from the existing layout, the proposed layout using the Group Technology Layout is the most appropriate choice.

Conclusion

The proposed layout of production using Group Technology Layout has a line efficiency of 79.59%, which shows that this layout is an efficient solution to improve production performance in CV. The new era of the panel. With the improvement of this layout, it is expected that the company can meet customer orders better and more on time, as well as optimize the use of resources in the production process. The implementation of this improvement will not only reduce operational costs, but also increase customer satisfaction through faster and more efficient product delivery.

Recommendations

Based on the results of this study, the following recommendations are made:

  1. CV. The new era of the panel should immediately apply the proposed layout using the Group Technology Layout to improve production efficiency and reduce operational costs.
  2. The company should train its employees on the new layout and provide them with the necessary tools and equipment to ensure a smooth transition.
  3. The company should continuously monitor and evaluate the performance of the new layout to ensure that it meets the expected results.
  4. The company should consider implementing other improvements, such as automation and robotics, to further enhance production efficiency and reduce operational costs.

Limitations of the Study

This study has several limitations that should be noted:

  1. The study only focused on the production floor layout of CV. The new era of the panel and did not consider other factors that may affect production efficiency, such as worker productivity and equipment maintenance.
  2. The study used a case study approach, which may not be generalizable to other manufacturing companies.
  3. The study did not consider the potential impact of the new layout on employee morale and job satisfaction.

Future Research Directions

This study provides several opportunities for future research:

  1. Investigating the impact of the new layout on employee morale and job satisfaction.
  2. Examining the effectiveness of the Corelap algorithm in other manufacturing industries.
  3. Developing a more comprehensive model that considers other factors that affect production efficiency, such as worker productivity and equipment maintenance.

Conclusion

In conclusion, this study demonstrates the effectiveness of the Group Technology Layout and Corelap algorithm in improving production efficiency and reducing operational costs in CV. The new era of the panel. The proposed layout using the Group Technology Layout has a line efficiency of 79.59%, which shows that this layout is an efficient solution to improve production performance in the company. With the improvement of this layout, it is expected that the company can meet customer orders better and more on time, as well as optimize the use of resources in the production process.
Q&A: Proposed Improvement in the Layout of the Production Floor using Group Technology Layout and Corelap Algorithm on CV. The New Era of the Panel

Q: What is the main problem that CV. The new era of the panel is facing in terms of production floor layout?

A: The main problem that CV. The new era of the panel is facing is an inefficient layout of production floors, which results in unnecessary movements, such as backtracking and cross movements, and a distance that is too far between the production station.

Q: What is the Group Technology Layout (GTL) method, and how does it help improve production efficiency?

A: The Group Technology Layout (GTL) method is a layout design approach that aims to group similar production stations together to minimize unnecessary movements and reduce the total movement and cost of handling material. This method helps improve production efficiency by reducing the distance between production stations and minimizing unnecessary movements.

Q: What is the Corelap algorithm, and how does it help improve production efficiency?

A: The Corelap algorithm is a computer-based algorithm that is used to optimize the layout of production floors. This algorithm uses a mathematical model to analyze the production process, identify the production stations, and determine the optimal layout that minimizes unnecessary movements and reduces the total movement and cost of handling material. The Corelap algorithm helps improve production efficiency by reducing the distance between production stations and minimizing unnecessary movements.

Q: What are the benefits of implementing the proposed layout using the Group Technology Layout and Corelap algorithm?

A: The benefits of implementing the proposed layout using the Group Technology Layout and Corelap algorithm include:

  • Reduced total movement and cost of handling material
  • Improved production efficiency
  • Increased line efficiency
  • Reduced operational costs
  • Increased customer satisfaction through faster and more efficient product delivery

Q: How does the proposed layout using the Group Technology Layout and Corelap algorithm compare to the existing layout?

A: The proposed layout using the Group Technology Layout and Corelap algorithm has a line efficiency of 79.59%, which is higher than the existing layout. The proposed layout also reduces the total movement and cost of handling material, making it a more efficient solution.

Q: What are the limitations of the study?

A: The study has several limitations, including:

  • The study only focused on the production floor layout of CV. The new era of the panel and did not consider other factors that may affect production efficiency, such as worker productivity and equipment maintenance.
  • The study used a case study approach, which may not be generalizable to other manufacturing companies.
  • The study did not consider the potential impact of the new layout on employee morale and job satisfaction.

Q: What are the future research directions?

A: The future research directions include:

  • Investigating the impact of the new layout on employee morale and job satisfaction.
  • Examining the effectiveness of the Corelap algorithm in other manufacturing industries.
  • Developing a more comprehensive model that considers other factors that affect production efficiency, such as worker productivity and equipment maintenance.

Q: What are the recommendations for CV. The new era of the panel?

A: The recommendations for CV. The new era of the panel include:

  • Implementing the proposed layout using the Group Technology Layout and Corelap algorithm to improve production efficiency and reduce operational costs.
  • Training employees on the new layout and providing them with the necessary tools and equipment to ensure a smooth transition.
  • Continuously monitoring and evaluating the performance of the new layout to ensure that it meets the expected results.
  • Considering implementing other improvements, such as automation and robotics, to further enhance production efficiency and reduce operational costs.