RELAYOUT OF PRODUCTION FACILITIES TO MINIMIZE DISTANCE AND COST OF MATERIAL HANDLING IN PT.IPK

Abstract

PT. IPK is a renewable manufacturing company that produces body part of air cooler generator, the function of air cooler generator is to convert the heat inside generator by using water or oil as mediator. Within two years, the demand of body part air cooler generator has been increased because of many power plants are driven by alternative resources such as water, air, biogas, nuclear, and others. The increasing demands must be supported by suitable strategies. In 2018, the company cannot support the demand as much 55%. It caused by processing time to produce body part air cooler generator takes 55 days. One of factor that influenced a processing time to produce the product is total movement of material handling. Currently, the total movement of material handling is 3,643.48 meters, while the current layout is not concerning the adjacent facilities based on material flow by re-layout the production facility is an alternative chosen to solved this problem, by choosing product layout is suitable for rearrange proposed layout, gather and analyze the information of initial layout and data required before generate new layout by using BLOCPLAN software, then analyze alternative layout that refers to main problem of the company to be selected, the total movement of proposed layout reduced become 3,181.44 meters from initial layout. The result of proposed layout has been generated by BLOCPLAN software reduces material handling cost from IDR 48,794,255.05, to IDR 42,606,517.61.