The Importance of Facility Layout Design

Oct 13, 2025 by windailys.com 144 views

Introduction

PT. Apindowaja Effective Persada is a manufacturing company that specializes in producing spare parts for oil palm industry machines. Located in Medan, North Sumatra, the company has been facing challenges in the flow of its production process due to the preparation of machines based on the same function (process layout). The high moment of material transfer and irregularities in the production flow occur due to the less-than-optimal facilities. In this article, we will discuss the re-design of facilities at PT. Apindowaja Effective Persada using the Group Technology approach based on Rank Order Clustering (ROC) and Blocplan Algorithm.

The Challenges of PT. Apindowaja Effective Persada

PT. Apindowaja Effective Persada produces various spare parts, including the mainshaft, cone, cone guide, pully, hydraulic cylinder, intermediate gear, gearbox, protect nuts, screw worms, and many others. Although the company has a wide range of products, the preparation of machines based on the same function (process layout) causes challenges in the flow of the production process. The high moment of material transfer and irregularities in the production flow occur due to the less-than-optimal facilities. This not only affects the efficiency and effectiveness of the production process but also increases the overall cost of production.

The Importance of Facility Layout Design

The facility layout design plays a crucial role in the efficiency and effectiveness of the production process. A well-designed facility layout can improve the flow of materials, reduce the moment of material transfer, and increase the overall productivity of the company. In contrast, a poorly designed facility layout can lead to inefficiencies, irregularities in the production flow, and increased costs. Therefore, it is essential to redesign the facilities at PT. Apindowaja Effective Persada to improve its efficiency and effectiveness.

The Group Technology Approach

The Group Technology approach is a method of grouping products that have similarities in terms of their design, production process, and material requirements. This approach not only makes it possible to group products that have similarities but also improves interactions between departments in the production process. By applying the Group Technology approach, PT. Apindowaja Effective Persada can redesign its facilities to improve the flow of materials and increase the overall productivity of the company.

Rank Order Clustering (ROC) Method

The Rank Order Clustering (ROC) method is a technique used to group products that have similarities in terms of their design, production process, and material requirements. This method involves ranking the products based on their similarities and then grouping them into clusters. By applying the ROC method, PT. Apindowaja Effective Persada can identify the products that have similarities and group them together to improve the flow of materials and increase the overall productivity of the company.

Blocplan Algorithm

The Blocplan algorithm is a method used to determine the proximity between factory facilities. This algorithm takes into account the location of the facilities, the flow of materials, and the production process to determine the optimal layout of the facilities. By applying the Blocplan algorithm, PT. Apindowaja Effective Persada can determine the proximity between its factory facilities and redesign its facilities to improve the flow of materials and increase the overall productivity of the company.

Results of the Analysis

The results of the analysis show that the rearrangement of the proposed facilities can reduce the moment of material transfer to 39.6%. Meanwhile, the value of closeness between new factory facilities using the Blocplan algorithm reaches 0.45. This shows a significant increase in efficiency, where the time processing of the entire spare parts can be shortened. That way, the effectiveness of the flow of materials at PT. Apindowaja Effective Persada also experienced significant improvement.

Conclusion

In conclusion, the re-design of facilities at PT. Apindowaja Effective Persada using the Group Technology approach based on Rank Order Clustering (ROC) and Blocplan Algorithm has proven to be a strategic step that will help the company remain competitive and adapt to the changing market needs. This redesign not only solves the existing problems but also creates a stronger foundation for future growth. By applying this approach, PT. Apindowaja Effective Persada can improve the efficiency and effectiveness of its production process, increase its overall productivity, and remain competitive in the market.

Recommendations

Based on the results of the analysis, the following recommendations are made:

PT. Apindowaja Effective Persada should apply the Group Technology approach based on Rank Order Clustering (ROC) and Blocplan Algorithm to redesign its facilities.
The company should identify the products that have similarities and group them together to improve the flow of materials and increase the overall productivity of the company.
The company should use the Blocplan algorithm to determine the proximity between its factory facilities and redesign its facilities to improve the flow of materials and increase the overall productivity of the company.
The company should monitor the performance of its production process and make adjustments as necessary to ensure that the redesigned facilities are meeting the company's goals and objectives.

Future Research Directions

Future research directions include:

Investigating the impact of the Group Technology approach on the efficiency and effectiveness of the production process.
Developing a more advanced algorithm for determining the proximity between factory facilities.
Investigating the impact of the Blocplan algorithm on the efficiency and effectiveness of the production process.
Developing a more comprehensive model for redesigning facilities that takes into account multiple factors, including the production process, material flow, and company goals and objectives.

Q: What is the Group Technology approach?

A: The Group Technology approach is a method of grouping products that have similarities in terms of their design, production process, and material requirements. This approach not only makes it possible to group products that have similarities but also improves interactions between departments in the production process.

Q: What is the Rank Order Clustering (ROC) method?

A: The Rank Order Clustering (ROC) method is a technique used to group products that have similarities in terms of their design, production process, and material requirements. This method involves ranking the products based on their similarities and then grouping them into clusters.

Q: What is the Blocplan algorithm?

A: The Blocplan algorithm is a method used to determine the proximity between factory facilities. This algorithm takes into account the location of the facilities, the flow of materials, and the production process to determine the optimal layout of the facilities.

Q: What are the benefits of re-designing facilities at PT. Apindowaja Effective Persada?

A: The benefits of re-designing facilities at PT. Apindowaja Effective Persada include:

Improved efficiency and effectiveness of the production process
Reduced moment of material transfer
Increased overall productivity of the company
Improved flow of materials
Increased competitiveness in the market

Q: How can PT. Apindowaja Effective Persada apply the Group Technology approach?

A: PT. Apindowaja Effective Persada can apply the Group Technology approach by:

Identifying the products that have similarities
Grouping the products together based on their similarities
Improving interactions between departments in the production process
Redesigning its facilities to improve the flow of materials and increase the overall productivity of the company

Q: How can PT. Apindowaja Effective Persada use the Blocplan algorithm?

A: PT. Apindowaja Effective Persada can use the Blocplan algorithm by:

Determining the proximity between its factory facilities
Redesigning its facilities to improve the flow of materials and increase the overall productivity of the company
Monitoring the performance of its production process and making adjustments as necessary

Q: What are the future research directions for re-designing facilities at PT. Apindowaja Effective Persada?

A: The future research directions for re-designing facilities at PT. Apindowaja Effective Persada include:

Investigating the impact of the Group Technology approach on the efficiency and effectiveness of the production process
Developing a more advanced algorithm for determining the proximity between factory facilities
Investigating the impact of the Blocplan algorithm on the efficiency and effectiveness of the production process
Developing a more comprehensive model for redesigning facilities that takes into account multiple factors, including the production process, material flow, and company goals and objectives.

Q: What are the recommendations for PT. Apindowaja Effective Persada?

A: The recommendations for PT. Apindowaja Effective Persada include:

Applying the Group Technology approach based on Rank Order Clustering (ROC) and Blocplan Algorithm to redesign its facilities
Identifying the products that have similarities and grouping them together to improve the flow of materials and increase the overall productivity of the company
Using the Blocplan algorithm to determine the proximity between its factory facilities and redesign its facilities to improve the flow of materials and increase the overall productivity of the company
Monitoring the performance of its production process and making adjustments as necessary to ensure that the redesigned facilities are meeting the company's goals and objectives.