Re -design Of The Layout Of Production Facilities At PT. Inti Jaya Metal Using Craft Algorithm And Blocplan Algorithm

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Re-design of the Layout of Production Facilities at PT. Inti Jaya Metals with Craft and Blocplan Algorithms

Introduction

The layout of production facilities is a crucial element that affects the performance of a company. At PT. Inti Jaya Metals, which is engaged in metal casting, initial observations indicate an ineffectiveness on the production floor. The amount of inefficient material transfer can cause increased costs and affect productivity. This is exacerbated by the existence of a work station whose use of the area is not optimal and the existence of a pile of damaged goods and the remaining cleaning that consumes space that should be used for production.

The Importance of Layout Redesign

To overcome this problem, it is necessary to re-design the production floor layout. This redesign process will focus on reducing the moment of material transfer and the preparation of more effective goods. In this case, we will use the Craft Algorithm (Computerized Relative Allocation of Facilities Technique) and the Blocplan Algorithm (Block Layout Planning) as a tool to redesign the layout. In addition, the 5S method will also be applied to improve the efficiency of space and workplace comfort.

Analysis of the Moment of Displacement

Before making a redesign, it is essential to know that the moment of the initial layout transfer reached 459,399.3 meters of transfer per year. This figure shows how far the material must be moved from one work station to another work station in the production process. The higher this value, the greater the costs incurred for material transfer.

The moment of displacement is a critical factor in determining the efficiency of a production facility. It not only affects the productivity of the company but also has a significant impact on the operational costs. By reducing the moment of displacement, companies can increase their productivity and reduce their operational costs.

Application of the Craft Algorithm

After the application of the craft algorithm, the moment of displacement can be reduced to 334,304.3 meters of transfer per year, providing material handling efficiency of 27.23%. This shows that the rearrangement of the layout carried out not only succeeded in reducing the distance of the transfer but also has the potential to increase productivity and reduce operational costs.

The craft algorithm is a computerized relative allocation of facilities technique that is used to design the layout of production facilities. It is a powerful tool that can help companies to reduce the moment of displacement and increase their productivity.

Application of the Blocplan Algorithm

In addition to the craft algorithm, the blocplan algorithm is also used to redesign the layout of production facilities at PT. Inti Jaya Metals. The blocplan algorithm is a block layout planning technique that is used to design the layout of production facilities. It is a flexible and adaptable technique that can be used to design the layout of production facilities in various industries.

5S Method for the Preparation of Goods

In addition to reducing the moment of transfer, the preparation of goods is also very important in creating a better work environment. The 5S method, which consists of seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain), are applied to organize the work area to make it neater and more efficient.

The 5S method is a powerful tool that can help companies to create a better work environment. It not only increases the aesthetics of the workplace but also reduces the time spent looking for goods and equipment. By involving operators in this process, companies can create awareness and responsibility for their work environment, which in turn will increase comfort and productivity.

Implementation of the 5S Method

In the context of PT. Inti Jaya Metals, the proposal for the application of 5S includes the removal of equipment that is not used and tidy up scattered goods. The implementation of the 5S method not only increases the aesthetics of the workplace but also reduces the time spent looking for goods and equipment.

Conclusion

Re-design of the Layout of Production Facilities at PT. Inti Jaya metal using the craft and blocplan algorithm has shown significant results in reducing the moment of material transfer. In addition, the application of the 5S method not only helps in the preparation of goods effectively but also increases the work environment. With these steps, PT. Inti Jaya Metals can increase operational efficiency and face challenges in the metal casting industry better.

Recommendations

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

  1. The craft algorithm and the blocplan algorithm should be used to redesign the layout of production facilities at PT. Inti Jaya Metals.
  2. The 5S method should be applied to organize the work area and make it neater and more efficient.
  3. The operators should be involved in the implementation of the 5S method to create awareness and responsibility for their work environment.
  4. The moment of displacement should be continuously monitored and reduced to increase productivity and reduce operational costs.

By following these recommendations, PT. Inti Jaya Metals can increase its operational efficiency and face challenges in the metal casting industry better.
Frequently Asked Questions (FAQs) about Re-design of the Layout of Production Facilities at PT. Inti Jaya Metals

Q: What is the main objective of re-designing the layout of production facilities at PT. Inti Jaya Metals?

A: The main objective of re-designing the layout of production facilities at PT. Inti Jaya Metals is to reduce the moment of material transfer and increase productivity and reduce operational costs.

Q: What are the benefits of using the craft algorithm and the blocplan algorithm in re-designing the layout of production facilities?

A: The benefits of using the craft algorithm and the blocplan algorithm in re-designing the layout of production facilities include reducing the moment of material transfer, increasing productivity, and reducing operational costs.

Q: What is the 5S method and how does it help in re-designing the layout of production facilities?

A: The 5S method is a technique that consists of seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain). It helps in re-designing the layout of production facilities by organizing the work area, making it neater and more efficient, and reducing the time spent looking for goods and equipment.

Q: How does the 5S method involve operators in the re-designing process?

A: The 5S method involves operators in the re-designing process by creating awareness and responsibility for their work environment. This is achieved by involving operators in the implementation of the 5S method and encouraging them to take ownership of their work area.

Q: What are the key steps in implementing the 5S method in re-designing the layout of production facilities?

A: The key steps in implementing the 5S method in re-designing the layout of production facilities include:

  1. Sorting (Seiri): Removing equipment that is not used and tidying up scattered goods.
  2. Setting in Order (Seiton): Organizing the work area to make it neater and more efficient.
  3. Shining (Seiso): Cleaning the work area to make it more efficient.
  4. Standardizing (Seiketsu): Establishing standards for the work area to ensure consistency.
  5. Sustaining (Shitsuke): Maintaining the standards established in the previous steps.

Q: What are the potential challenges in re-designing the layout of production facilities at PT. Inti Jaya Metals?

A: The potential challenges in re-designing the layout of production facilities at PT. Inti Jaya Metals include:

  1. Resistance to change from operators and management.
  2. Limited resources and budget.
  3. Complexity of the production process.
  4. Limited expertise in re-designing the layout of production facilities.

Q: How can PT. Inti Jaya Metals overcome the potential challenges in re-designing the layout of production facilities?

A: PT. Inti Jaya Metals can overcome the potential challenges in re-designing the layout of production facilities by:

  1. Communicating the benefits of re-designing the layout of production facilities to operators and management.
  2. Allocating sufficient resources and budget for the re-designing process.
  3. Seeking expertise from consultants or experts in re-designing the layout of production facilities.
  4. Implementing a phased approach to re-designing the layout of production facilities.

Q: What are the potential benefits of re-designing the layout of production facilities at PT. Inti Jaya Metals?

A: The potential benefits of re-designing the layout of production facilities at PT. Inti Jaya Metals include:

  1. Increased productivity.
  2. Reduced operational costs.
  3. Improved quality of products.
  4. Enhanced competitiveness in the market.

Q: How can PT. Inti Jaya Metals measure the success of re-designing the layout of production facilities?

A: PT. Inti Jaya Metals can measure the success of re-designing the layout of production facilities by:

  1. Monitoring the moment of material transfer.
  2. Tracking productivity and operational costs.
  3. Conducting regular audits to ensure compliance with standards.
  4. Gathering feedback from operators and management.