MULTI-CRITERIA LAYOUT DESIGN OF MIXED PRODUCTION LINE CONSIDERING PROCESS NEEDS OF NEW PRODUCT

• Main Author: Arifiyanto, Agus
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/49405
• Institution: Institut Teknologi Bandung

In the high technology era, a manufacturing has to quick response toward variety of customer needs, but always maintain competitiveness advantage of their product through improvement efficiency of production process. Thus, appropriate manufacturing strategy selection including design layout, it can improve productivity and significantly reduce operational cost of the company. This research is based on a case study of automotive company that facing on redesigning layout for their new product in the current mixed production line system and facilities to reduce cost. Thus, the result of this research can contribute to provide solution to management. The objective of this research are how to fulfill remaining space and redesign layout to get the best layout for producing new product. Heuristic combination approach between construction and improvement algorithm is used for redesigning manufacturing mixed production line with spine layout. Construction algorithm is arranged for initial layout design with some scenarios based on process sequence in current operation. Those initial layout will be improved by using software CRAFT with always check each iteration to avoid left-sub process move to right side and vice versa. Material handling cost is commonly used as criteria in redesigning layout. This research developed multi-criteria or MCDM (Multi Criteria Decision Making) in redesign layout as requirement to produce new product. Alternative layouts will be evaluated comprehensively by using multi-criteria, not only evaluate material handling cost. In this research, those multi criteria are material handling cost, total relayout cost, takt time process, numbers of shutdown period for relocation and comply with management policy related with safety. Based on those criterias, AHP (Analytic Hierarchy Process) is used for decision making on selecting the best layout from all alternatives. Through this research we got the best layout by relocate finish good stock to upper level with free space 1,120 m2 for new process. We also got 4 alternative spine layouts and will be evaluated by using multi criteria such as material handling cost, total relayout cost, takt time, numbers of shutdown period, and management policy related with safety. Through AHP method for decision making, the best layout was selected with material handling cost 6,685, total relayout cost 54.8 billion rupiah and required 10 days shutdown for relayout. The best layout also has considered takt time in each sub process and comply with management policy related with safety matters.