1.

Background
Storage in the manufacturing industry is an important role, it is impossible for the production to
be distributed directly to all its customers. This results in the need for a good warehouse and
storage system. A good warehouse does not have to be large in size because if it is supported
by a good storage system and a good inventory, the warehouse utilization can be maximized.
Based on warehouse research conducted by Petra University Industrial Engineering Students
(internet journal, Facility Layout Design, downloaded on June 8, 2011 via http: //
www.digilib.petra.ac.id), the most important thing in a warehouse is that most raw materials
must be moved to be produced so that they are not stored in the warehouse for too long. This
will result in damage to these raw materials and increase storage costs. Products that are
moved to be marketed to consumers will generate income, while products that are not moving
and stored in the warehouse for too long will not generate income. The first priority in the
warehouse is "keep the goods moving fast and moving quickly".
The problems faced by plastic factories occur in the warehouse for raw materials and finished
products. The lack of good procedure for arranging goods in the warehouse causes problems in
the warehouse, so that the warehouse seems cramped and less organized. Warehouse layout
conditions that are not based on a comprehensive layout design can lead to inefficiencies in
material retrieval and storage times and make it difficult for operators to handle materials due
to the limitations of the warehouse. Previous research on warehouse layout, Muhammad
Ilham, Faculty of Industrial Engineering, University of North Sumatra, downloaded on 19 July
2011 via an internet journal) provides a comparison between the previous warehouse layout
and the proposed layout:
1. Average material handling mileage per month for old warehouse layouts
much longer than the proposed warehouse layout.
2. By using the proposed warehouse layout, it will be obtained
easy checking of goods in the warehouse. By using a warehouse card, the loading and unloading
arrangements will be easier because it can be seen which area is empty for the product to be
found and the location of the product to be sent which will be easily identified.
Meanwhile, the warehouse layout research was conducted by Roy Hanggara
2007 concluded that after repairing the warehouse or warehouse relayout, there was a change
in storage area for the two types of raw materials. Until now, the company's inventory control
has not run optimally considering the fact that there are frequent delays in raw materials and
excess inventory. By using the Q system (Continius Review Model) or an inventory control
system with a fixed number of orders and the time interval varies, the total cost obtained is
smaller than the P system (The Period Review Fixed order Internal) or inventory system with a
time interval between two the order is fixed while the number of goods ordered varies.

2. Problem Formulation
The main problems that will be discussed are:
- How to plan the location of the storage area for raw materials and finished products
in the warehouse?
- What is the average production per month?
- What is the average raw material inventory per month?
3. Research Objectives
The aim of this research is :
1. Determine the planning of the location of the storage area for raw materials and finished
products
on the warehouse.
2. Calculate the average production per month.
3. Calculate the average raw material inventory per month.
4. Research Benefits
- For the company
Make a warehouse layout design for smooth warehousing activities and flow
- For Unisbank
This research activity is expected to be a means to further enhance the cooperation
relationship between Unisbank and manufacturing companies in the city of Semarang and its
surroundings. In addition, it is also useful for teaching staff to implement the knowledge
obtained in theory to solve problems in the industrial world and to expand the knowledge of
teaching staff that can be obtained from outside the campus environment.
5. Literature review
5.1. Definition of Layout Design
Layout design is defined as the design of a factory layout as the planning and integration of the
flow of the components of a product to obtain the most effective and efficient interrelation
between operators, equipment, and the material transformation process from receiving to
product delivery (James M. Apple, Factory Layout and Material Transfer, translated by
Nurhayati Mardiono, ITB, Bandung, 1990). Based on the facility planning hierarchy and the
definition of layout design that has been described previously, the definition of layout design
used in this final project is the configuration of a production work station which is arranged
based on interactions between departments that meet certain criteria so that the interaction is
optimal in the transformation process. materials from raw materials to finished products.
Planning the layout of production facilities is an important issue, because the factory or
industry will operate for a long time, errors in the analysis and layout planning will result in
ineffective and inefficient production activities. Layout planning is one of the facilities planning
stages which aims to develop an effective and efficient production system so as to achieve a
production process with the most economical cost. The study of facility layout arrangement is
always related to minimizing the total cost. Included in the cost elements are construction
costs, installation costs, material handling costs, production costs, safety costs, in-process
storage costs. In addition, careful planning of the facility layout will provide convenience when
plant expansion is needed or supervision is required.

5.2. Warehouse
5.2.1. Warehouse definition
According to David E Mulcahy, (Warehouse and Distribution Operation Handbook International
Edition, McGraw Hill, New York, 1994) warehouse is a function of storing various types of
products that have storage units in large or small quantities within the time the product is
produced by the factory. (seller) and when a product is needed by a customer or work station in
a production facility. The warehouse is a place that is burdened with tasks to store goods that
will be used in production, until the goods are requested according to the production schedule.
Warehouses or storage in general will have a fairly important function in maintaining the
smooth operation of a factory's production. Here there are three main objectives of this
department relating to the procurement of goods (Wignjosoebroto, 2003), which are as
follows:
1. Supervision, namely with an administrative system that is well maintained for
control the entry and exit of the material. This task also concerns the security of
material, that is, don't lose it.
2. Selection, namely maintenance activities so that the material is stored inside
warehouse not quickly damaged in storage.
3. Hoarding / storing, namely so that at any time the material is needed
required will remain available before and during the process.
4. Planning the layout of machines and departments in the factory.
5.3. The Shared Strorage method
In an effort to reduce storage space requirements on dedicated
storage, some warehouse managers use a variation of dedicated storage where the final
product placement is more carefully managed. Typically from time to time different results use
the same slot for storage, even if the final product only occupies that slot once. To support the
consideration of shared storage, if the arrival of 100 pallets with a large number of "fast
moving" of the product for storage. The bulk of these pallets will be reused and will be shipped
as many as 5 pallets per day within 20 days.

5.4. Material Transfer

Materials can be moved manually or using automatic methods, materials can be moved once or
a thousand times. Materials can be allocated to fixed or random locations or materials can be
placed on the floor or above. If there are two work stations / departments I and j whose
coordinates are shown as (x, y) and (a, b), several methods can be used to calculate the
distance between the two center points, namely:
1. Rectilinear Distance
The distance is measured along a trajectory using a line perpendicular to one another. An
example is material moving along rectilinear aisles in the plant.

dij =│x-a│+│y-b│

2. Euclidean Distance
the distance is measured along a straight line between two points. Euclidean distance
can be illustrated as a straight conveyor that cuts two work stations.
 dij = √[(x2-x1)2 + (y2-y1)2]

3. Squared Euclidean Distance

The distance is measured along the actual path that passes between two points. For example,
in a guided vehicle system, the vehicle on its way must follow the directions that have been
determined on the controlled track network. Therefore, the flow path distance can be longer
compared to rectilinier or Euclidean.
dij = (x-a) 2 + (y-b) 2

6. Research Results
Determination of the Required Storage Area Determination of the Required Storage Area
The storage area used is wooden pallets, to save area 2 levels are collected on each pallet with
a 2 x 2 arrangement, so each pallet consists of 8 sacks of product or 8 sacks of raw materials,
done to facilitate the arrangement of products to the storage area and also to save space
utilization. So the area of one storage area is:
Storage Area = (2) product length x (2) product width Storage Area = (2) 1 m x (2) 1 m = 4 m2

Determination of Alley Width (Aisle)

The aisle is used as an alley or material handling path, movement
transfer of personnel, The material handling used is a handpallet. So the required aisle is based
on the need for the line according to the dimensions of the handpallet. The determination of
the required aisle area is based on twice the longest dimension, namely the width of the
handpallet when carrying the product. The image can be seen in Figure 5.6
Aisle Space = 2 x width of material traversing
Aisle Space = 2 x 1 m = 2 m
Warehouse Area Requirement = (Storage Area x Total Area
Storage) + Aisle
7. Conclusion
After collecting data at the plastic factory warehouse, several conclusions can be drawn,
including:
1. The required number of storage areas is 16 areas, with details of 8 areas for raw material
storage pallets and 8 areas for raw material storage pallets.
2. The total area for space requirements for storage pallets for raw materials and finished
products is 64 m².
3. One pallet area is collected in 2 levels with the arrangement of 2 x 2, so each pallet consists
of 8 sacks of product or 8 sacks of raw materials.
4. The width of the alley or aisle is 2 m, so the total space requirement for the aisle is 96 m ².
5. The results of the shared storage method will be maximized if used in a plastic factory
warehouse that has 2 types of products.
8. Suggestions
1. The warehouse area is sufficient, it's just that good procedures are needed in the product
placement process, so that the use of handpallets is more effective.
2. The application of the shared storage method is very good for companies, because it can
save the mileage of handpallets.
3. Provision of bulkheads at the warehouse location is reduced so that the movement of
materials is not too far, and can give a broad impression to the eye.
4. The use of goods cards or item codes in warehouses can also simplify the process of placing
products in empty areas and also provide information that facilitates the loading and unloading
process and product checking.
5. Companies may consider using wheeled pallets to save time moving goods.
6. The company can apply this proposed layout to the finished product and raw material w