Bambang Darmawan - Document

PERENCANAAN FASILITAS

Kuliah -01
Bambang Darmawan - Document

TUJUAN INSTRUKSIONAL
• Memahami konsep dan metoda untuk
perencanaan fasilitas pada sistem
manufaktur tradisional dan non-tradisional
dan sistem jasa
• Mampu untuk menerapkan konsep dan
metoda yang diberikan dalam
perancangan tata letak fasilitas sistem
tersebut.
Bambang Darmawan - Document

PERENCANAAN FASILITAS:
Silabus Ringkas
• Pengantar Perencanaan Fasilitas pada sistem
manufaktur dan sistem jasa,
• Teknologi Kelompok dan Tata Letak sistem
manufaktur,
• Implementasi Teknologi Kelompok pada sistem
manufaktur,
• Tata Letak Fasilitas untuk sistem jasa,
• Tata Letak Dinamik,
• Tata Letak Maya,
• Tata Letak Fleksibel,
• Warehouse,
• Lokasi Fasilitas
• Algoritma lanjut untuk masalah tata letak.
Bambang Darmawan - Document

REFERENSI

• Sunderesh Heragu, Facilities Design, PWS

Publishing Company, 1997
• Tompkins, J. A. White, Y. A. Bozer, E. H.
Frazelle, J. M. A. Tanchoco, and J. Trevino,
Facilities Planning, Wiley, 1996
• Makalah dari jurnal internasional
Bambang Darmawan - Document

EVALUASI
• Kehadiran minimal 80%
• Tugas (30%)
• Ujian Tengah Semester (30%)
• Ujian Akhir Semester (30%)
• Presentasi dan keaktifan dalam diskusi di
kelas (10%)
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PENGANTAR PERENCANAAN
FASILITAS
Bambang Darmawan - Document

Facilities Planning (FP)

[Tompkins, et.al. 1996]
• A facility represents the tangible fixed assets
associated with a locus of economic activity
• Economic activities are those activities
associated with the production, distribution,
and consumption of goods and/or services.
• Examples of facilities –manufacturing plants
or factories, warehouses, distribution centers,
retail stores, hospitals, offices, airports,
universities/schools.
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Facilities Planning (FP)

[Tompkins, et.al. 1996]
• FP involves determining the type, quantity,
arrangement, and location of tangible fixed assets
to best achieve the objectives of the economic
activity.
• For example: A factory that enables low cost
production of a product can be utilized to maximize
the profit of a firm
• For an airport: enables the passenger-airline interface
• For a hospital: supports providing medical care to
patients.
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Facility Planning Hierarchy

• Divide into two general areas: Facility design and
Facility location
• Facility location: Determine where facilities should
be located to best support the production and
distribution of of goods and/or services.
• Facility design: Determine how the components of a
facility should be configured to best support the
production and distribution of goods and/or services,
where the components of the facility consist of the
structure, the layout, and the material handling
systems.
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PERENCANAAN FASILITAS

Lokasi
Fasilitas

Perencanaan
Fasilitas Desain
Struktur

Desain
Desain Tata Letak
Fasilitas
Desain Sistem
Pemindahan
Material
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Facility Planning Hierarchy

• Structural Design: Determine the detailed design of a facility,
including the building and services –e.g. gas, water, power,
heat, light, air, and sewage.
• Facility Layout: Determine the arrangement and shape of
space-consuming entities (or “activities”) in a facility, where
the activities interact with each other through flows of
materials, personnel, and/or information.
• Material Handling System Design: Determine the process,
equipment, and systems that transfer and manage the transfer
of material between activities in a facility
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PERENCANAAN FASILITAS
UNTUK PABRIK

Lokasi
Pabrik

Perencanaan
Fasilitas
Pabrik Desain
Struktur Pabrik

Desain
Tata Letak Pabrik
Pabrik

Pemindahan
Material
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Facilities Planning (FP)

• FP involves making strategic decisions
concerning the tangible fixed assets used
in the production process.
• The difference in the planning horizon for
each of the different levels of analysis
used in the production process listed in
Table 1.1.
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Frame Work for Facilities Design

[Q. Lee, IIE Solution, 1997]
• Layout or space planning involves five levels -from
the global maps of site location to engineering
drawing tools and workstations
• Level 1: Global site location
• Level 2: Supra-space plan
• Level 3: Macro-space plan
• Level 4: Micro-space plan
• Level 5: Sub-micro-space plan
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Level 1: Global site location

• The firm decide where to locate facilities
and determine their missions
• The most strategic impact
• Major considerations: labor rates,tax
break, labor skill and attitudes, supporting
services, politics,etc.
• Appropriate planning results in facilities
optimized for the markets and located
near the most important resources
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Bambang Darmawan - Document

Level 2: Supra-space plan

• Site planning, including number, size,
location of buildings, as well as roads,
water, gas, and rail
• Involve a series of drawing showing past,
present and future configurations
• Planning still has long-term and far
reaching consequences.
Bambang Darmawan - Document
Bambang Darmawan - Document
Bambang Darmawan - Document
Bambang Darmawan - Document

Level 3: Macro-space plan

• A macro-layout, plans each building,
structure, or sub-unit of the site
• The designers define and locate operating
departments and determine overall
material flow.
• Easier to correct than site level decisions
• A poorly planned facility can bring high
handling cost, confusion, and inflexibility
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Bambang Darmawan - Document

Level 4: Micro-space plan

• Department or cell layout
• Location of specific equipment is
determined
• Emphasis shifts from gross material flow
to personal space and communication
• Socio-technical considerations dominate
Bambang Darmawan - Document
Bambang Darmawan - Document

Level 5: Sub-micro-space plan

• Workstation design
• Workstations are designed for efficiency,
effectiveness, and safety
• Tools-jig and fixture
• Location of materials
• Appropriate material handling aids
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Bambang Darmawan - Document

Table 1.1: Planning Horizon Associated with

Production Analysis
Planning Horizon Level of Analysis
Months-Years Facilities Planning

Months-Years Product design and Process Planning

Weeks-Months Production Planning

Hours-Weeks Production control

Minutes-Hours Quality control

Seconds-Minutes Machine-level real-time control

Bambang Darmawan - Document

Significance of Facility Design

• Material handling costs:
- 30-75% of a product’s cost (Sule 1991)
- 20-50% of a manufacturing company’s
operating budget (Tompkins & White, 1994)
• Optimal Layout Design can reduce
production costs
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What is Facility Layout

• Location or arrangement of
everything within & around buildings
• Objectives are to maximize
 Customer satisfaction
 Utilization of space, equipment, & people
 Efficient flow of information, material, & people
 Employee morale & safety
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Objectives of Facility Layout

• Minimize material handling costs
• Utilize space and labour efficiently
• Eliminate bottlenecks
• Reduce manufacturing cycle time
• Eliminate waste or redundant movement
• Facilitate the entry, exit, and placement of
material, products, or people
• Improved employee morale and safer working
conditions
• Improved customer/client interaction
• Provide flexibility to adapt to changing conditions
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TYPES OF LAYOUT
PROBLEMS:[Heragu, 1998]
• Service systems layout problems
• Manufacturing layout problems
• Warehouse layout problems
• Nontraditional layout problems
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Types of Layouts
• Fixed-position layout
• Process-oriented layout
• Office layout
• Retail layout
• Warehouse layout
• Product-oriented layout
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Office Layout Floor Plan

Accounting
Finance
Fin. Acct.

Manager Brand X
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Retail /Service Layout -

Grid Design
Grocery Store
Bread Meat

Produce Frozen Foods

Milk

Check-
Office Carts
out
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Emergency Room Layout

E.R.Triage Patient A -
broken leg
room
Patient B - erratic
pacemaker

Hallway

E.R. beds Pharmacy Billing/exit

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Warehouse Layout Floor Plan

Conveyor
Truck

Zones Order Picker

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Six Layout Strategies

• Fixed-position layout
 large bulky projects such as ships and
buildings
• Process-oriented layout
 deals with low-volume, high-variety
production (“job shop”, intermittent
production)
• Office layout
 positions workers, their equipment, and
spaces/offices to provide for movement of
information
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Six Layout Strategies - continued

• Retail/service layout
 allocates shelf space and responds to
customer behavior
• Warehouse layout
 addresses trade-offs between space and
material handling
• Product-oriented layout
 seeks the best personnel and machine use
in repetitive or continuous production
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Requirements of a Good Layout

 an understanding of capacity and
space requirements
 selection of appropriate material
handling equipment
 decisions regarding environment and
aesthetics
 identification and understanding of
the requirements for information flow
 identification of the cost of moving
between the various work areas
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Constraints on Layout Objectives

• Product design & volume

• Process equipment & capacity
• Quality of work life
• Building and site
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Layout Strategies, Examples, and

Criteria
Layout strategy Example Criteria
Service/retail Drug store Expose customer to high
Grocery store margin items
Department store
Storage Distributor Minimize storage and
Warehouse handling costs
Product oriented TV assembly line Minimize line imbalance,
delay, and idle time
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Areas of Concern in Layout

Strategy/Design

Communication

Service Material
Areas Attributes
Layout
Work
Warehousing Strategy
Cell

Material
Safety
Flow