USULAN PERANCANGAN TATA LETAK PABRIK, GUDANG MATERIAL, DAN GUDANG PRODUK JADI DI CV MA MEKAR RUBBER

• Main Author: Ikhwan Naufal, Fikri
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/76288
• Institution: Institut Teknologi Bandung

CV MA Mekar Rubber is a company engaged in the processing of used rubber, particularly in the field of grinding of used rubber. It was established in 1986. As the company has grown, the demand for Mesh products (products resulting from the grinding of used rubber) has been increasing every year. In early 2023, CV MA Mekar Rubber received a proposal for a collaboration to become a permanent supplier for a manufacturer in Kapuk, which is planned to begin in the late third quarter or early fourth quarter. The collaboration offer was projected and it was determined that around 1,330 bags of finished products per week would need storage space, while the current storage capacity can only accommodate approximately 960 bags of finished products per week. Similarly, in terms of material requirements, it was projected that around 2,085 bags of materials per week would need storage space, while the capacity can only accommodate around 2,070 bags. Apart from the insufficient storage capacity, the current storage method, which is still done traditionally using the block stacking principle, also leads to transportation and movement-related waste issues, consuming about 19% of the working time per day on non-value-added activities. The proposal involves designing the layout of the entire factory, the layout of the finished product warehouse, and the layout of the material warehouse to help CV MA Mekar Rubber accommodate orders in 2023 and minimize transportation and movement-related waste issues. Various types of optimization models for warehouse design are developed based on the number of blocks, the objective function used, and the storage policies employed. The optimization models are solved using two types of programs. The warehouse model with one block and the warehouse model with two blocks using random storage policy are solved using the global solver in LINGO, while the warehouse model with two blocks using dedicated storage policy and class-based storage policy is solved using MATLAB genetic algorithm live editor. Then, the allocation of goods/classes to the warehouse is performed to determine the most optimal placement that minimizes the annual travel distance. Finally, the constructed warehouse is integrated with other facilities using the BLOCPLAN algorithm to form the overall layout. The results of the iteration of the warehouse design model and allocation model show that for the product warehouse, the best alternative is a warehouse with two blocks, using the objective function of travel distance and employing the class-based storage policy. This warehouse is expected to have an annual travel distance of 107,286 meters, a total area of 229.24 square meters, and a total storage capacity of 96 pallets. As for the material warehouse, the best alternative is a warehouse with two blocks, using the objective function of travel distance and employing the class-based storage policy. This warehouse is expected to have an annual travel distance of 141,022 meters, a total area of 370.28 square meters, and a total storage capacity of 180 pallets. Finally, the selected overall layout design based on the BLOCPLAN algorithm requires an area of 1,869.005 square meters, with an adjacency score performance criterion value of 0.67 and a relative distance score performance criterion value of 0.73.