Kuliah-Responsi Versi B TATA LETAK

Redesigning a Process
Through Layout Revision

Define
scope
2
Identify Document
opportunity process
1 3
Implement Evaluate
changes performance
6 4
Redesign Process
(Revise layout)
5
Figure 7.1
To Accompany
Krajewski & Ritzman
Absolute Locations
Frozen
foods Meats
Dry
groceries
Bread Vegetables
(a) Original layout

Figure 7.2
To Accompany
Krajewski & Ritzman
Absolute Locations
Frozen
Meats
foods
Dry
groceries
Vegetables Bread
(b) Revised layout

Figure 7.2
To Accompany
Krajewski & Ritzman
Layout Types
Grinding Forging Lathes
Painting Welding Drills
Milling
Office machines Foundry
(a) Layout of a job shop

Figure 7.3
To Accompany
Krajewski & Ritzman
Layout Types
Station 1 Station 2 Station 3 Station 4
(b) Layout of a production line
Figure 7.3
To Accompany
Krajewski & Ritzman
Group Technology
One Worker, Multiple Machines Machine
2
Machine
Machine 3
1
Materials in
Finished
goods out
Machine
Figure 7.4 Machine 4
To Accompany 5
Krajewski & Ritzman
Group Technology
Lathing Milling Drilling
L L M M D D
D D
L L M M
Grinding
L L M M
G G
L L Assembly
G G
A A
Receiving and A A G G
shipping
(a) Jumbled flows in a job shop without GT cells Figure 7.5

To Accompany
Krajewski & Ritzman
Group Technology
L L M D G Assembly
area
Cell 1 Cell 2 A A
Receiving L M G G
Cell 3
L M D
Shipping
(b) Line flows in a job shop with three GT cells Figure 7.5
To Accompany
Krajewski & Ritzman
Office of Budget
Management
Department Area Needed (ft2)
1. Administration 3,500
2. Social services 2,600
3. Institutions 2,400
4. Accounting 1,600
5. Education 1,500
6. Internal audit 3,400
Total 15,000
3 6 4
100'
1 2 5
Figure 7.6
To Accompany 150'
Krajewski & Ritzman
Office of Budget 3 6 4
Management
100'
1 2 5
150'
Trips between Departments

Department 1 2 3 4 5 6
1. Administration — 3 6 5 6 10
2. Social services — 8 1 1
3. Institutions — 3 9
4. Accounting — 2
5. Education — 1
6. Internal audit —
To Accompany
Krajewski & Ritzman
Management
100'
1 2 5
150'
 Departments 1 and 6 close together

100'
1 5
150'
To Accompany
Figure 7.7
Krajewski & Ritzman
Management
100'
1 2 5
150'

6 3
100'
1 5
150'
To Accompany
Figure 7.7
Krajewski & Ritzman
Management
100'
1 2 5
150'

6 2 3
100'
1 4 5
150'
To Accompany
Figure 7.7
Krajewski & Ritzman
Management
100'
1 2 5
150'

6 2 3
100'
1 4 5
150'
To Accompany
Figure 7.7
Krajewski & Ritzman
Out-and-Back Warehouse
Storage area
3 5 5 6 4 2 7
Dock Aisle
1 5 5 4 4 2 7
Storage area
Figure 7.10
To Accompany
Krajewski & Ritzman
Zone Systems
Zones Zones Control
station Shipping
Click to add title doors
Tractor
trailer
Tractor
trailer
Feeder Feeder
lines lines Overflow
To Accompany
Figure 7.11
Krajewski & Ritzman
Design Product Layouts: Line
Balancing
Line balancing is the process of assigning tasks to workstations
in such a way that the workstations have approximately the same
processing time requirements. This results in the minimized idle time
along the line and high utilization of labor and equipment.
4 tasks 2 tasks
Worker 1 Worker 2
Each task takes 1 minutes, how to balance?
Cycle time is the maximum time allowed at each workstation

to complete its set of tasks on a single unit
What is the cycle time for the system above?
17
Parallel Workstations
30/hr. 30/hr. 30/hr. 30/hr.

1 min. 1 min. 2 min. 1 min.
Bottleneck
30/hr. 2 min. 30/hr.
60/hr. 60/hr.
1 min. 1 min. 1 min.
30/hr.
2 min. 30/hr.
Parallel Workstations
18
The obstacle
• The difficulty to forming task bundles that have the
same duration.
• The difference among the elemental task lengths
can not be overcome by grouping task.
– Ex: Can you split the tasks with task times {1,2,3,4} into
two groups such that total task time in each group is the
same?
– Ex: Try the above question with {1,2,2,4}
• A required technological sequence prohibit the
desirable task combinations
– Ex: Let the task times be {1,2,3,4} but suppose that the
task with time 1 can only done after the task with time 4 is
completed. Moreover task with time 3 can only done after
19 the task with time 2 is completed. How to group?
Cycle Time
The major determinant: cycle time
Cycle time is the maximum time allowed at each

workstation to complete its tasks on a unit.
Minimum cycle time: longest task time by

assigning each task to a workstation
Maximum cycle time: sum of the task time by
assigning all tasks to a workstation
20
Determine Maximum Output
Cycle Time: Time to process 1 unit
OT: OperatingTimePerDay
D: DesiredOutputRate
OT
 DesiredCycleTime
D
CT  CycleTime  FromProcessDesign
OT
 CT Can produce at the desired level, design is feasible
D
OT
 CT Cannot produce at the desired level, design is infeasible
D
Example: If a student can answer a multiple choice question in 2 minutes

but gets a test with 30 questions and is given only 30 minutes then
OT=30 minutes; D=30
Desired
21 cycle time=1 minute < 2 minutes = Cycle time from the process
capability
Determine the Minimum Number
of Workstations Required: Efficiency
Example: Students can answer a multiple choice question in 2 minutes but
given a test with 30 questions and is given only 30 minutes. What is the
minimum number of students to collaborate to answer all the questions in
the exam?
Total operation (task) time = 60 minutes = 30 x 2 minutes
Operating time=30 minutes
60/3=2 students must collaborate. This Nmin below.
Total task time for all products produced in a day (D)( t)
N min = 
Availabale time in a day OT
N min 
t 
Total task time for a product  t

OT/D Availabale time for a product CT
 t = sum of task times

22
Percent Idle Time
I
dle
timeperc
yc
le
P
er
cen
tid
le
tim
e=
(
N)(
CT)
Efficiency = 1 – Percent idle time
23
Example 1: Precedence Diagram
Precedence diagram: Tool used in line
balancing to display elemental tasks and
sequence requirements
0.1 min. 1.0 min.
a b
c d e
0.7 min. 0.5 min. 0.2 min.
24
Example 1: Assembly Line
Balancing
• Arrange tasks shown in the previous slide
into workstations.
– Use a cycle time of 1.0 minute
• Every 1 minute, 1 unit must be completed
– Rule: Assign tasks in order of the most number
of followers
• If you are to choose between a and c, choose a
• If you are to choose between b and d, choose b
• Number of followers: a:3, b:2, c:2, d:1, e:0
– Eligible task fits into the remaining time and all
25
of its predecessors are assigned.
Solution to Example 1.
Assigning operations by the number
Work-
of
Time
followers
Assign Station
Work- Time Assign Station
Station
Station Remaining
Remaining Eligible
Eligible Task
Task Idle
IdleTime
Time
11 1.0
1.0 a,c
a,c aa
.9
.9 cc cc
.2
.2 none
none -- .2
.2
22 1.0
1.0 bb bb
00 none
none -- 00
33 1.0
1.0 dd dd
.5
.5 ee ee
.3
.3 -- -- .3
.3
.5
.5
- Eligible operation fits into the remaining time and its predecessors are already
assigned
26 .
- What is the minimum cycle time possible for this example?
Calculate Percent Idle Time
Sum of idle times at stations during a cycle

Percent idle time =
(N)(CT)  Total station ti me
0.2  0  0.3
Percent idle time =  0.167  16.7%
(3)(1)
Efficiency=1-percent idle time=1-0.167=0.833=83.3%
27
Line Balancing Heuristic Rules
• Assign tasks in order of most following
tasks.
• Assign task in the order of the greatest task
time.
• Assign tasks in order of greatest positional
weight.
– Positional weight is the sum of each task’s
time and the times of all following tasks.
28
Solution to Example 1. Assigning
operations using their task times.
Work-
Work- Time
Time Assign
Assign Station
Station
Station
Station Remaining
Remaining Eligible
Eligible Task
Task Idle
IdleTime
Time
11 1.0
1.0 a,c
a,c cc
.9
.9 aa aa
.2
.2 none
none -- .2
.2
22 1.0
1.0 bb bb
00 none
none -- 00
33 1.0
1.0 dd dd
.5
.5 ee ee
.3
.3 -- -- .3
.3
.5
.5
Eligible operation fits into the remaining time and its predecessors are already
assigned
29 .
Positional Weights
Assign tasks in order of greatest positional weight.
– Positional weight is the sum of each task’s time

and the times of all following tasks.
– a:1.8 mins; b: 1.7 mins; c:1.4 mins; d: 0.7 mins;
e:0.2 mins.
30
Solution to Example 1. Assigning
operations using their task times.
Work-
Work- Time
Time Assign
Assign Station
Station
Station
Station Remaining
Remaining Eligible
Eligible Task
Task Idle
IdleTime
Time
11 1.0
1.0 a,c
a,c aa
.9
.9 cc cc
.2
.2 none
none -- .2
.2
22 1.0
1.0 bb bb
00 none
none -- 00
33 1.0
1.0 dd dd
.5
.5 ee ee
.3
.3 -- -- .3
.3
.5
.5
Eligible operation fits into the remaining time and its predecessors are already
assigned
31 .
Example 2
0.2 0.2 0.3

a b e
0.8 0.6
c d f g h
1.0 0.4 0.3
32
Solution to Example 2
Station 1 Station 2 Station 3 Station 4
a b e
f g h
c d
33
Line Balancing
Green Grass, Inc.

Big Broadcaster
Line Balancing Big Broadcaster
Work Time Immediate

Element Description (sec) Predecessor(s)
A Bolt leg frame to hopper 40 None
B Insert impeller shaft 30 A
C Attach axle 50 A
D Attach agitator 40 B
E Attach drive wheel 6 B
F Attach free wheel 25 C
G Mount lower post 15 C
H Attach controls 20 D, E
I Mount nameplate 18 F, G
Total 244
Example 7.3
Work Time Immediate

C Attach axle 50 A
Total 244
Example 7.3
Work Time Immediate

C Attach axle 50 A
Total 244
A
40
Example 7.3
Work Time Immediate

C Attach axle 50 A
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
Total 244
A
40
Example 7.3
Work Time Immediate

C Attach axle 50 A
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
Total 244
A
40 C
50
Example 7.3
Work Time Immediate

B
C
Insert impeller shaft
Attach axle
30
50
A
A
D
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
40
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
Total 244
A
40 C
50
Example 7.3
Work Time Immediate

B
C
Attach axle
30
50
A
A
D
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
40
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
E
Total
A
244
6
40 C
50
Example 7.3
Work Time Immediate

B
C
Attach axle
30
50
A
A
D
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
40
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
E
Total
A
244
6
F
40 C 25
50
Example 7.3
Work Time Immediate

B
C
Attach axle
30
50
A
A
D
E
F
Attach drive wheel
Attach free wheel
6
25
B B
C
40
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
E
Total
A
244
6
F
40 C 25
50
G
Example 7.3 15
Work Time Immediate

B Insert impeller shaft 30 A D
C
D
Attach axle
Attach agitator
50
40
A
B
H
E Attach drive wheel 6
B B 40
F Attach free wheel 25 C 20
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
E
Total
A
244
6
F
40 C 25
50
G
Example 7.3 15
Work Time Immediate

B Insert impeller shaft 30 A D
C
D
Attach axle
Attach agitator
50
40
A
B
H
E Attach drive wheel 6
B B 40
F Attach free wheel 25 C 20
H
I
Attach controls
Mount nameplate
20
18
30 D, E
F, G
E
Total
A
244
6
F
40 C 25
50 I
18
G
Example 7.3 15
D
H
B 40
20
30 E
A 6
F
40 C 25
50 I
18
G
Figure 7.12 15
• Desired output rate, r must be matched to the
staffing or production plan.
 Cycle time, c is the maximum time allowed for work on a unit at

each station:
1
c=
r
• Desired output rate, r = 2400 unit/week
Plant operates 40 hours/week
r = 2400/40 = 60 units/hour
 Cycle time, c = 1/60

= 1 minute/unit 1
= 60 seconds/unit r
Theoretical minimum (TM ) - sum of all work-element
standard times divided by the cycle time.
TM = 244 seconds/60 seconds = 4.067

It must be rounded up to 5 stations
Cycle time: c = 1/60 = 1 minute/unit = 60 seconds/unit
Efficiency (%) - ratio of productive time to total time.
Efficiency = [244/5(60)]100 = 81.3%
Balance Delay - amount by which efficiency falls short of 100%.
(100 − 81.3) = 18.7%

c = 60 seconds/unit
TM = 5 stations D
Efficiency = 81.3% H
B 40
20
S1 30 E
S3 6
A S4
S2 F
Cumm Idle
Station CandidateS5
Choice Time Time
40 C 25 S1 A A 40 20
50 S2 B,C C
I 50 10
S3 B,F,G B 30 30
E,F,G 18
F 55 5
G
Figure 7.13 15
The goal is to cluster the work elements Green Grass, Inc.
into 5 workstations so that the number of
work-stations is minimized, and the cycle Line Balancing Solution
time of 60 seconds is not violated. Here
we use the trial-and-error method to find
a solution, although commercial software
packages are also available.
D
H
B 40
20
S1 30 E
S3
A S4 6
S2
F S5
40 C 25
50 I
c = 60 seconds/unit
TM = 5 stations 18
G
Efficiency = 81.3%
© 2007 Pearson Education 15
From-To Chart
• Processes:
– X, Y, Z, Q, and R
• Parts that are manufactured through these
processes:
– Part No’s.: 1, 2, & 3
From-To Chart
To X Y Z Q R Total
From
Total
From-To Chart
To X Y Z Q R Total
From
X 1
Y 1
Z 1
R 1
Total
Process Sequence: Part No. 1= X to Y to Z to R to Q

From-To Chart
To X Y Z Q R Total
From
1 2
X
Y 1
Z 2 1
Q 2
R 1
Total
Process Sequence: Part No. 2= X to Z to Q to R

From-To Chart
To X Y Z Q R Total
From
1 3 2
X
Y 1 3
Z 2 3 1
Q 2 3
R 1
Total
Process Sequence: Part No. 3= X to Y to Z to Q to R

From-To Chart
To X Y Z Q R Total
From
1 3 2 3
X
Y 1 3 2
Z 2 3 1 3
Q 2 3 2
R 1 1
11
Total 2 3 3 3 11
Soal 1
Tata letak sebuah rumah sakit ditunjukkan sebagai berikut
Proses Exam Exam 10’

X-Ray
Awal Room-1 Room 2
(4)
(1) (2) (3)
Cast-Setting
Ruang Ruang
Lab EKG Room 10’
Operasi Recovery
(5) (8)
(6) (7)
40’
Adapun pergerakan jumlah pasien antar diperlihatkan

sebagai berikut :
(1) (2) (3) (4) (5) (6) (7) (8)
(1) 100 100
(2) 50 20
(3) 30 30
(4) 20 20
(5) 20 10
(6) 30
(7)
(8)
Tentukan tata letak yang optimal berdasarkan

orientasi proses
Soal 2
Pada proses registrasi mahasiswa, pihak institusi telah
menyiapkan empat ruangan yaitu ruang pengambilan
formulir (A), ruang advising (B), Ruang Kartu (C) dan ruang
verifikasi/pembayaran
Pergerakan mahasiswa diantara ruang yang ada
ditunjukkan oleh diagram dari-ke (from-to) sbb :
A B C D Tata letak yang ada

A 450 550 50 A B C D
B 200 200 0
C 0 0 750 30’ 30’ 30’
D 0 0 0
Tentukan optimasi tata letak ruang berdasarkan orientasi
proses
Soal 3
Diagram dari-ke sebuah kegiatan pada sebuah dapur

adalah sebagai berikut
Rfg Ctr Sink Sto Stv

(1) (2) (3) (4) (5)
(1) 8 13 0 0
(2) 5 3 3 8
(3) 3 12 4 0
(4) 3 0 0 5
(5) 0 8 4 10
Tentukan bentuk tata letak yang paling baik berdasarkan

orientasi proses
(1) (2) (3) (4) (5)
4 4
4 4 4 4
(2) (3) (4)
4 4
5 5
(1) (2) (3) 3 8 8
(1) 11 11 (5)
8 13
12 (4)
10 8
(1) Refrigerator
4
14 (2) Counter
(5)
(3) Sink
(4) Storage
(5) Stove
Soal 4
Sebuah industri memiliki target produksi sebanyak 500 unit
perminggu dengan waktu efektif kerja sejumlah 4000 menit
per minggu. Pengerjaan produk tersebut dilakukan melalui
proses (tugas) sebagai berikut
Tugas waktu (menit) tugas sebelumnya
A 5 -
B 3 A
C 4 B
D 3 B
E 6 C
F 1 C
G 4 D,E,F
H 2 G
Tentukan waktu siklus, jumlah stasiun kerja, dan efisiensi.

Gambarkan diagram precedence kegiatan tsb
Soal 5
Sebuah industri perakitan perahu menyediakan waktu
sebanyak 200 menit per harinya untuk kegiatan perakitan
perahu. Permintaan setiap harinya adalah 60 unit perahu.
Adapun kegiatan perakitan dapat diuraikan dengan tugas-
tugas sebagai berikut :
A 1 -
B 1 A
C 2 A
D 1 C
E 3 C
F 1 C
G 1 D,E,F
H 2 B
I 1 G,H
Tentukan kondisi keseimbangan lini yang diinginkan

sehingga kegiatan dapat optimal
Soal 6
Sebuah perusahaan minuman memiliki waktu kerja 5 jam per hari dan
5 hari seminggu, mempunyai target permintaan sebesar 3000 botol
per minggu Pengerjaan produk tersebut dilakukan melalui proses
(tugas) sebagai berikut
1 0,1 -
2 0,1 1
3 0,1 2
4 0,2 2
5 0,1 2
6 0,2 3,4,5
7 0,1 1
8 0,1 7
9 0,2 7,8
10 0,1 9
11 0,2 6
12 0,2 10,11
13 0,1 12

Kuliah-Responsi Versi B TATA LETAK

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Kuliah-Responsi Versi B TATA LETAK

Hochgeladen von

Copyright:

Verfügbare Formate

Redesigning a Process

Through Layout Revision

(a) Original layout

(b) Revised layout

Grinding Forging Lathes

Painting Welding Drills

(a) Layout of a job shop

Station 1 Station 2 Station 3 Station 4

(b) Layout of a production line

(a) Jumbled flows in a job shop without GT cells Figure 7.5

Trips between Departments

 Departments 1 and 6 close together

 Departments 1 and 6 close together

 Departments 1 and 6 close together

 Departments 1 and 6 close together

Click to add title doors

Each task takes 1 minutes, how to balance?

Cycle time is the maximum time allowed at each workstation

30/hr. 30/hr. 30/hr. 30/hr.

30/hr. 2 min. 30/hr.

The major determinant: cycle time

Cycle time is the maximum time allowed at each

Minimum cycle time: longest task time by

Example: If a student can answer a multiple choice question in 2 minutes

 t = sum of task times

Efficiency = 1 – Percent idle time

Sum of idle times at stations during a cycle

Efficiency=1-percent idle time=1-0.167=0.833=83.3%

Assign tasks in order of greatest positional weight.

– Positional weight is the sum of each task’s time

0.2 0.2 0.3

Station 1 Station 2 Station 3 Station 4

Green Grass, Inc.

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

Work Time Immediate

 Cycle time, c is the maximum time allowed for work on a unit at

 Cycle time, c = 1/60

TM = 244 seconds/60 seconds = 4.067

Cycle time: c = 1/60 = 1 minute/unit = 60 seconds/unit

Efficiency (%) - ratio of productive time to total time.

Efficiency = [244/5(60)]100 = 81.3%

Balance Delay - amount by which efficiency falls short of 100%.

(100 − 81.3) = 18.7%

Process Sequence: Part No. 1= X to Y to Z to R to Q

Process Sequence: Part No. 2= X to Z to Q to R

Process Sequence: Part No. 3= X to Y to Z to Q to R

Proses Exam Exam 10’

Adapun pergerakan jumlah pasien antar diperlihatkan

Tentukan tata letak yang optimal berdasarkan

A B C D Tata letak yang ada

Diagram dari-ke sebuah kegiatan pada sebuah dapur

Rfg Ctr Sink Sto Stv

Tentukan bentuk tata letak yang paling baik berdasarkan

Tugas waktu (menit) tugas sebelumnya