Flow , Space & Activity

Relationships
TI4101 Facility Layout
Video ini dibuat hanya bertujuan sebagai
materi daring yang pendistribusiannya
terbatas pada media pembelajaran di
lingkungan Institut Teknologi Bandung.
Penggunaan konten sebagian maupun
keseluruhan untuk kepentingan lainnya
dapat berkonsultasi langsung dengan
Kelompok Keahlian Sistem Manufaktur
Institut Teknologi Bandung.

TI4101 Facility Layout | Group Technology Layout 2

Tujuan & Prasyarat
• Tujuan Instruksional Umum
• Mahasiswa mampu m e r a n ca n g tata letak fasilitas sistem
manufaktur, yang meliputi mesin, tempat kerja, dan gudang
serta sistem pemindahan materialnya.

• Tujuan Khusus
• Memahami pengaruh aliran produksi, luas lantai dan
keterkaitan antar aktivitas produksi dalam perancangan
tata letak pabrik.

TI4101 Facility Layout | Flow, Space & Activity Relationship 3

Introduction

Three im p o r t a n t co n s id e r a t io n s in determining the

requirement of a facility:

o Flow

o Space

o Activity Relationships

TI4101 Facility Layout | Flow, Space & Activity Relationships 4

Flo w Pla n n in g
Planning effective flow involves combining the flow patterns
given before.

• Department Layout

• Machine Layout

• Workstation Layout

TI4101 Facility Layout | Flow, Space & Activity Relationship 5

Flo w Pr o ce s s e s

Flow Within Activities Analysis Level

Motion Studies and
Workstation or machine Motions
Ergonomics
Machines and
Department Machine Layout
workstations
Facility Departments Department Layout

TI4101 Facility Layout | Flow, Space & Activity Relationship 6

Co m b in in g Wo r k s t a t io n s
• A s ys t e m a t ic a p p r o a ch should be used in combining
workstations into department

• Procedural guide for combining workstations (See Table 4.1)

• Organizations using modern manufacturing approaches are

combining production, support, administrative, and service
planning departments to cr e a t e in t e gr a t e d
d e p a r t m e n t s –e.g. a manufacturing cell

TI4101 Facility Layout | Flow, Space & Activity Relationship 7

Co m b in in g Wo r k s t a t io n s :
Pr o ce d u r a l Gu id e

TI4101 Facility Layout | Flow, Space & Activity Relationship 8

De p a r t m e n t a l Pla n n in g
• Departments can involve production, support, administrative, and
service areas

• Pr o d u ct io n De p a r t m e n t s : Collections of workstations

• Depending on p r o d u ct vo lu m e -va r ie t y, production department

can be classified as:
• Product (Production Line) Departments
• Process Departments
• Fixed Material Location Departments
• Product Family Departments

TI4101 Facility Layout | Flow, Space & Activity Relationships 9

Flo w Pa t t e r n s
• Product flows beginning to e n d
• Being transformed from raw material semi finished  finished
products

• General flow patterns Type of Layout

–S shaped • Product layout
–W shaped • Process layout
–U shaped • Fixed position layout
–I shaped
• Group technology-based
–Dendrite layout
–Spine
• Hybrid layout

TI4101 Facility Layout | Flow, Space & Activity Relationship 10

De p a r t m e n t (o r La yo u t )
Product
Cla s s ifica t io n

Variety

TI4101 Facility Layout | Flow, Space & Activity Relationship 11

Gr o u p in g o f Pa r t s

Parts Before Grouping Parts After Grouping

Source: Indiamart, 2018 Source: Mectips, 2018

TI4101 Facility Layout | Flow, Space & Activity Relationship 12

Ma n u fa ct u r in g Ce ll
• Manufacturing Cells
• Gr o u p s : machines, employees, materials, tooling, and
material handling and storage equipment to produce
families of parts.

• The most important benefits are achieved when the

cells are designed, controlled, and operated using JIT,
TQM, and TEI

TI4101 Facility Layout | Flow, Space & Activity Relationship 13

A Flo w Pr o ce s s
• The flow of materials within a manufacturing facility:
the material flow system (See Fig. 4.9 and 4.10)

• The flow of products from a manufacturing facility:

the physical distribution system (See Fig. 4.11)

• The material management, material flow, and

physical distribution system form a logistic system
(See Fig. 4.12)

TI4101 Facility Layout | Flow, Space & Activity Relationship 14

 Th e Ma t e r ia l Flo w Sys t e m
Drill A W
S Lathe Drill Grind
S A
T S R
Press Bend Drill
O E H
(a)
R Lathe Drill M O
E B U
S Mill Lathe Drill L S
Y E

W
Lathe Press Grind
S A
T R
O H
(b)
R O
E U
S Weld Paint Assembly S
E

TI4101 Facility Layout | Flow, Space & Activity Relationship 15

 Th e Ma t e r ia l Flo w Sys t e m
Lathe Drill Grind Assembly
S S
T Mill Assembly Weld Paint T
(c)
O O
R Press Lathe Drill Press Assembly R
E E
S Grind Drill Assembly Drill Grind S

Lathe Lathe Drill Weld Weld

S S
T Lathe Lathe Drill Paint Paint T
(d) O O
R Mill Mill Grind Assembly R
E E
S Mill Mill Grind Assembly S

TI4101 Facility Layout | Flow, Space & Activity Relationship 16

Th e Flo w Sys t e m

TI4101 Facility Layout | Flow, Space & Activity Relationship 17

A Lo gis t ic Sys t e m

TI4101 Facility Layout | Flow, Space & Activity Relationship 18

Me a s u r e Flo w
• Quantitative Flow Measurement
• Am o u n t m o ve d between facilities (Departments or
Workstations)

• Qualitative Flow Measurement

• Clo s e n e s s Re la t io n s h ip Values developed by Muther.
• Aspects considered are:
• Organizational relationships
• Personnel flow relationships
• Control relationships
• Environmental relationships
• Process relationships
TI4101 Facility Layout | Flow, Space & Activity Relationship 19
Qu a lit a t ive flo w
• Level of interaction between machine pairs
• Frequency of trips  From -to chart
–Calculation from OPC

WAREHOUSE CUTTING DRILL LATHE MILLING ASSEMBLY

WAREHOUSE 5 6 - 9 -
CUTTING 4 3 6
DRILL 2 5 3
LATHE 3 4 3
MILLING 6 3
ASSEMBLY 4 5 6

TI4101 Facility Layout | Flow, Space & Activity Relationship 20

Qu a lit a t ive Re la t io n s h ip
Consideration • Systematic qualitative approach
1. Material Flow • Muther (1973)  adjacency
2. Personnel Flow relationships  RELATIONSHIP
3. Same resource CHART
4. Same personnel Code Description Color
A Absolutely necessary
5. Communication
E Especially important
6. Safety I Important
7. Noise O Ordinary
U Unimportant
8. Structural
X Undesirable

TI4101 Facility Layout | Flow, Space & Activity Relationship 21

Act ivit y Re la t io n s h ip Ch a r t

1 Form
A

1 I
2 Trim
E 2 O

2 U 2 U
3 Treat
X U
22

3 E
4 Assembly
U 2

5 Pack and Ship

TI4101 Facility Layout | Flow, Space & Activity Relationship 22

Flo w Pa t t e r n

• Flow Within Workstation (motion studies and ergonomics

considerations)

• Flow Within Departments (See Fig. 4.13 &4.14)

• Flow Between Departments (See Fig. 4.15 & 4.16)

TI4101 Facility Layout | Flow, Space & Activity Relationship 23

Flo w Wit h in De p a r t m e n t s :
Pr o d u ct La yo u t

TI4101 Facility Layout | Flow, Space & Activity Relationship 24

Flo w Wit h in De p a r t m e n t s :
Pr o ce s s La yo u t

TI4101 Facility Layout | Flow, Space & Activity Relationship 25

Flo w Be t w e e n De p a r t m e n t s

TI4101 Facility Layout | Flow, Space & Activity Relationship 26

Sp a ce Re q u ir e m e n t s
• In manufacturing and office environments, space requirements should
be d e t e r m in e d fir s t fo r in d ivid u a l w o r k s t a t io n s ; n e xt ,
d e p a r t m e n t s , etc.

• Modern manufacturing approaches can r e d u ce s p a ce requirements.

• Products are delivered to the points of use in s m a lle r lo t and unit
load size
• De ce n t r a lize d s t o r a ge areas
• Less inventories (using a p u lle d s ys t e m )
• Ma n u fa ct u r in g ce lls
• Companies are d o w n s izin g

TI4101 Facility Layout | Flow, Space & Activity Relationship 27

Sp a ce Re q u ir e m e n t s
Workstation Specification
• Eq u ip m e n t Sp a ce consists of space for
• the equipment; machine travel; machine maintenance;
• plant services
• Ma t e r ia ls Sp a ce consists of space for
• Receiving and storing materials; In-process materials;
• Storing and shipping materials; Storing and shipping waste and
scrap; Tools, fixtures, jig, dies, and maintenance materials
• Pe r s o n n e l a r e a consists of space for
• The operator; Material handling; Operator ingress and egress.

TI4101 Facility Layout | Flow, Space & Activity Relationship 28

 Wo r k s t a t io n

Vertical Mill

Workstation
In-Process
Materials

Bench
4" - 0"

Incoming
Materials
Tool Locker
24" x 16"

Workstation

TI4101 Facility Layout | Flow, Space & Activity Relationship 29

Ais le Wid t h
Table 4.4 Recommended Aisle Widths for Various Types of Flow
Type of Flow Aisle Width (centimeter)
Tractors 366
3-ton Forklift 335
2-ton Forklift 305
1-ton Forklift 274
Narrow aisle truk 183
Manual platform truk 152
Personnel 91
Personnel with doors opening into the aisle 183
from one side
Personnel with doors opening into the aisle 244
from two side

Source: Tompkins, 2010

TI4101 Facility Layout | Flow, Space & Activity Relationship 30

Ais le Allo w a n ce

Table 4.3 Aisle Allowance Estimates

If the Largest Load Is Aisle Allowance
Percentage Isa
Less than 0.6 m2 5-10
Between 0.6 m2 and 1.2 m2 10-20
Between 1.2 m2 and 1.8 m2 20-30
Greater than 1.8m2 30-40
aExpressed as a perentage of the net area required for

equipment, material, and personnel.

Source: Tompkins, 2010

TI4101 Facility Layout | Flow, Space & Activity Relationship 31

Co n t o h Lu a s La n t a i Gu d a n g Ba h a n Ba k u

• (1),(2),(3),(4) Diketahui
• (5) V Silinder = Π.R2.t ; V balok = p x l x t
32
• (6) Berdasarkan bahan yang disiapkan
• dari “Routing Sheet” x jumlah hari kerja/minggu
• (7) Kolom (5) x Kolom (6)
• (8) Diketahui 1 meter
• (9) Kolom (7) / Kolom (8)
• (10) Kolom (9) x Allowance X %
• (11) Kolom (9) + Kolom (10)
Pe n d e k a t a n la in d a la m p e r h it u n ga n lu a s
• Merujuk ke suatu standar tertentu. Misalnya:
–Undang-undang perkantoran Inggris (The Office Act)
–Standar Bapenas
– Standar instansi pemerintah (mis: Permen no 73 Tahun 2011 tentang standar luas
kantor atau Kepmen PU no 306/KPTS/1989)
–Standar asosiasi (mis: Asosiasi Asitektur Indonesia)

33