Analysis of Facility Layout Design to Improve Production Efficiency Using the Systematic Layout Planning (SLP) Method: A Case Study at CV. XYZ
DOI:
https://doi.org/10.52330/jtm.v24i2.547Keywords:
Facility Layout, Systematic Layout Planning, BLOCPLAN, Material Handling, Production EfficiencyAbstract
The increasing complexity of manufacturing systems requires companies to continuously improve production efficiency through effective facility layout design. CV. XYZ, a manufacturer of 10-ton wooden drums, experiences inefficiencies caused by long material handling distances, backtracking movements, and high operational costs resulting from its existing production layout. This study aims to optimize the facility layout using the Systematic Layout Planning (SLP) method integrated with BLOCPLAN software to identify the most efficient layout alternative. Primary data were collected through direct observation, time studies, interviews with production personnel, and documentation of workstation dimensions and production flow. The proposed layouts were evaluated using Activity Relationship Chart (ARC), Activity Relationship Diagram (ARD), material handling distance, travel time, and material handling cost (OMH). The results indicate that the SLP-based layout reduced material travel distance by 38%, travel time by 38%, and material handling cost by 25%, while the BLOCPLAN layout achieved reductions of 35%, 35%, and 20%, respectively. Compared with the algorithm-generated layout, the manually developed SLP layout provided superior operational efficiency while maintaining existing production constraints. The novelty of this research lies in the quantitative comparison between manual SLP and algorithm-based BLOCPLAN layouts for a complex wooden drum manufacturing process involving 31 production stages. The findings provide practical guidance for improving facility layout efficiency in wood-based manufacturing industries.
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