Applying a Systematic Layout Planning Method for Factory Layout Design

Abstract

Plant layout is the process of systematically planning and allocating space within a factory, considering the relationships between activities, production flow, and space constraints to maximize operational efficiency. This research aims to improve the production plant layout of an engine and agricultural machinery manufacturing by applying a systematic layout planning method (SLP) to increase space utilization efficiency, reduce redundant material handling, and lower production costs. Research operations using the SLP method start with (1) collecting data on plant layouts and production processes (PQRST), (2) analyzing production process activities, ( 3) analyzing relationships between activities, ( 4) calculating usable area, and ( 5) design alternative plant layouts. The tools used include flow charts, flow process charts, P-Q charts, from-to charts, activity relationship charts (ARC), and activity relationship diagrams (ARD). The data providers were 6 people, including the factory manager, production manager, human resources staff, and production line staff. Applying the systematic layout planning approach ( SLP) to data analysis and factory layout design resulted in a factory layout that reduced material handling distances in the production process. Research findings showed that production line A reduced handling distance by 77.1 meters (from 362.7 meters to 285.6 meters for alternative layout 2), and production line B reduced handling distance by 45.3 meters (from 197.5 meters to 152.2 meters for alternative layout 2). Reduce the number of path intersections in the production process, finding that the number of intersections decreased by 2 points (from 5 points to 3 points for alternative layout 2).