Redesign of The Production Facility Layout by Using Systematic Layout Planning Method at Cahaya Bintang Mas Company Surabaya

On the production floor at Cahaya Bintang Mas Company Surabaya, the arrangement of production facilities is not optimal because the material handling distance is quite far. One effort to overcome the problems that occur, then do the redesign of the facility layout that occurs on the production floor using the Systematic Layout Planning Method. The research was conducted in December 2018 until the research was completed. The data needed in this research are primary data obtained through measurement methods and secondary data obtained through data that has been researched and collected by other related parties. The results showed that the total distance of material handling distance for the current layout has a total distance of 508.6 m, By SLP method it can reduce matherial handilg distance, alternative 1 layout has a total distance of 324.8 meter (36,1%), and alternative layout 2 has a total distance of 215.5 meter(57,6


Introduction
One effort to overcome the above problems is to redesign the facility layout that occurs on the production floor. In this problem the proposed design of appropriate facility layout is using the method of systematic layout planning (SLP). There are many approaches in purposed in creating facility layouts. One of them is advanced algorithmic techniques such as genetic algorithm technique (Resende 2015). Cahaya Benteng Mas Company is a manufacturing company engaged in building materials that produce roof and wave walls, steel roof truss, cast floor supports, ceiling frames, flashing, capping, and coil roll. This company is a job order company where work is done if there is an order from the consumer. The arrangement of production facilities is not optimal because the material transfer distance is quite far, such as the distance of raw material warehouse with uncoiler machines which are 12 m to 15 m which can be minimized by reducing the width of the entrance in accordance with the standard width pathway that is equal to 5 m. Another problem is the material transfer distance from roll forming machine 750 1 to the far crimping machine that is equal to 21 m where this distance only requires about 1 m to 2 m, roll forming machine 750 1 must also pass through several machines causing a bottleneck that has an impact at the time of waiting for a longer crane so that it inhibits the production process on other products. Varsha Karandikar et al, 2017, asked that instead of selecting from either of the two layout, the team extrapolated the advantages of each layout and developed a new layout which was consideredto be the most optimal layout. D. Suhardini, et al, in their studying showed that the sue of systematic layout planning method reduce material handling cost of 10,98% . Furtermore Lei Wen and Lu Bai, 2015, a broad and detailed two stage index system of logistic facility layout has been establishes. Eliud Maina C, 2018 , SLP can be used to solve to study a viable procedure in solving a layout design and improvement problem. Result of a research showed that the rearrangement of the layout decrease distance-travel-time consumed in transportation and also consist of flow of material, result in a increase in productivity (Marthur Rashi, 2019) Based on above description, then formulation of the problem is "How redesign the layout of production facilities with the systematic layout planning method, whether it can minimize the material transfer distance at Cahaya Benteng Mas Company Surabaya? " The objectives of this study is to find out whether the systematic layout planning method can improve the layout of the product facilities currently in the light company.

Literature Review
Systematic layout planning is a systematic and organized layout design method. This method is used to design the best alternative layout and minimize the moment of material transfer that occurs on the production floor.. To keep up with the pace, the facility layout, akey element of facilities planning, has to be adaptable to changes (Chen, 2013). Futher the case study illustrations that it is viable procedure insolving a layout design and improvement problem .
Facility layout problem (FLP) can be interpreted as a procedure for setting up factory facilities to support the smooth production process. According to Poormustafa, 2011, FLP can be formulated differently but it is usully considered as an optimalization problem.
According Adil Baykasogl T.D, 2009, it can be showed that these variables effect the facility layoutand as such, itshould beflexible toaccomadate them. Then Maryam hamedi, 2012, the facility designers selectthese layout based on the degree of uncertainty in the production mix, the volume data forfuture needs revision of layout costs.
The application is expected to make the fastest material flow with the lowestcost and least amount of material handilng. (Muther R 1973/ And that corelap designed to accourdate situation when constantly changing condition prohibit the collection of precise data.( Chee Ailing, 2009). Fuhtermore producing product with high quality and provides good service with low cost in short time using the resources is the objective of property managing a facility (Heragu SS, 2008) Procedure to relayout the production floor consist of three steps, such an analyzing the existing layout, design the plant base SLP and the evaluation and selection of alternative layout (Law AK 2000). According to Tompkins, 2010, there are several steps in systematic layout planning, like the figure 1.

3,2. Variable identification
Based on the research title, the variables related to this study can be identified as follows: Independent variable (independent), consist of production floor area, number of production machines, production machine size, current layout, and distance of transfer of current layout material. And the dependent variable in this study is the distance of transfer of alternative layout materials.

Result and Conclusion 4.1. Result of Research
The First Lay Out can be illustrated as this bellow.

4.1.1.Material Flow
Material flow pattern for the production process at Cahaya Benteng Mas Company Surabaya is a Straight Line or flow pattern based on a straight line because the production process is short and relatively simple, consisting of only a few kinds of production equipment (production equipment).

Activity Relationship Chart (ARC)
ARC on the production floor illustrates the close relationship between existing facilities which is characterized by the degree of relationship along with the reasons.

Area needs
Sum of area needs for storage and warehouse area is 768 m 2 , machine production is 640.54 m 2 , and production facility is 3744 m 2. . The width of the entrance and exit of the raw material and the finishing goods are 12 meter and 5 meter, so that there is 7 m wide available. To utilize the area that is still available, an expansion of raw material warehouse and finished goods warehouse is carried out, so that the width of the raw material warehouse area and finished goods warehouse is added to 15 meter.   Percentage of efficiency in reducing total material transfer distance. Percentage of total distance reduction efficiency in the transfer of current layout materials and alternative layout 2 Persentase = Total distance first lay out -Total distance lay out alternative 2 x 100% Total distance lay out first = 512.6−215.5 512.6 100% = 57.9% From the table above it is known that SLP layout can shrten the material handilng distance from the first layout by 297,1 meter or 57,9%.

Conclusion
The results of the study showed that the layout design with systematic layout planning method could improve the transportation process of material handling, yit from the original distance of 512,6 meters to 215,5 meters or around 57,9 %. Thus systematic layout planning method can be applied very significance in this compony as an effort to increase productivity.