Redesign The Layout of Production Facilities at a Garment Company Using the BLOCPLAN Method to Optimize Material Handling

Abstract

Facility layout design is crucial in production layout setups. The composition of facilities that corresponds to the flow of materials between departments will help to ensure the production system's continuity. PT.  KMC is a garment company in West Jakarta that manufactures shirts, dresses, and t-shirt bloats. The company's current layout facilities have not run optimally. This is because inefficient movement distances result in wasted material handling costs, and crossing production flows between departments cause production processes to be disturbed. The objective of this project is to rethink facility layouts using the BLOCPLAN approach in order to optimize material handling. The BLOCPLAN approach may examine layout performance and generate new layout ideas for efficient material handling. The discussion is limited because this research was only conducted on one company. Based on the results of the layout redesign using the BLOCPLAN approach, various improvements were obtained, including a 37.12% increase in material handling cost efficiency. The proposed layout with the BLOCPLAN method is able to provide a reduction in material transfer distance of 22.6 meters and a material handling cost of Rp 155,346 when compared to the initial layout, which had a total overall displacement distance of 35.8 meters and an initial layout material handling cost of Rp 247,059, making it much cheaper.