Arief Rachim Saputra

(1)

by

ARIEF RACHIM SAPUTRA 1-12-120-95

BACHELOR’S DEGREE in

INDUSTRIAL ENGINEERING

FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang 15339 Indonesia

August 2016

(2)

Arief Rachim Saputra

STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

____________________________________________

Student Date

Approved by:

Dr. Ir. Yuki Indrayadi, MME

____________________________________________

Thesis Advisor Date

Ir. Setijo Awibowo, MM

____________________________________________

Thesis Co-Advisor Date

Dr. Ir. Gembong Baskoro, M. Sc

____________________________________________

Dean Date

(3)

Redesigning The Process and Layout of Parts Inventory To Increase the Performance of Logistic Department at PT.XYZ

By

Dr. Ir. Yuki Indrayadi, MME., Advisor Ir. Setijo Awibowo, MM., Co-Advisor

SWISS GERMAN UNIVERSITY

The warehouse is an essential section of every factory. The good system and design of the warehouse will explain the current state of the plant. PT.XYZ is one of the car assembler company located in Indonesia. Component of the car is imported from Germany. The quality and quantity of the received parts have never been checked until it goes to parts preparation. The shortage and quality issue are becoming a massive issue at PT.XYZ, causing continuous parts robbing and dominos effect to the other process.

The processes from receiving until the parts ready to assembled are observed. From the process observation, the SLP method and distribution centre idea are taken as the based methodology of this research but with several limitations to designing the new layout.

Redesigning the layout is performed by adding a new activity of checking, with its dedicated area inside the warehouse. The aim of this new checking area is to inspect the part-boxes before storing, in order to anticipate any quantity and quality problems of the received parts. Standard operating procedures while receiving is also made to become the guidelines for the employee.

Keywords: Layout Design, SLP, Warehouse

(4)

(5)

I dedicate my thesis to my family who have always been my nearest and have been so close to me whenever I needed. It is their unconditional love that motivates me to set

higher targets. I also dedicate this thesis to Industrial Engineering 2012 friends who have supported me and helped me constantly.

(6)

ACKNOWLEDGEMENTS

All the praises are for the almighty, Allah SWT, who bestowed me with the ability and potential to complete this thesis work within due course of time.

First, I would like to thank Dr. Ir. Yuki Indrayadi, MME. For his guidance, encouragement, and patience over the last six months. Thank you so much for forcing me and spent the free time to have me consulting.

Secondly, I would like to thank my Co- Advisor for forcing me to work on campus every day. Moreover, thankyou for guiding my thesis work, so it is done in time.

Thank you for Industrial Engineering 2012, especially, Dhika Mahaputra, Otje Aria, Hilman Satriawan and Willie Chandra for help and suggestions during this thesis work.

(7)

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF C ONTENTS ... 7

LIST OF FIGURES ... 10

LIST OF TABLES ... 11

CHAPTER 1 - INTRODUCTION ... 12

1.1 Background ... 12

1.2 Research Problems ... 16

1.3 Thesis Purpose ... 16

1.4 Thesis Scope ... 16

1.5 Thesis Limitation ... 16

1.6 Thesis Organization ... 17

CHAPTER 2 – LITERATURE REVIEW ... 18

2.1 Warehouse Layout ... 18

2.1.1 U-Flow Warehouse ... 18

2.1.2 Through Flow Warehouse ... 18

2.2 Aisle Design ... 19

2.2.1 Flying V Design ... 19

2.2.2 Fishbone ... 19

2.2.3 Chevron Aisles ... 19

2.3 Storage Design ... 19

2.3.1 Normal ... 19

2.3.2 Double Deep Racks ... 20

2.3.3 Drive-in Racks ... 20

2.3.4 Tier Racks ... 20

2.3.5 Live Storing ... 20

2.3.6 Carousels ... 20

2.4 Lean ... 21

2.5 Waste ... 22

2.5.1 Muda (Waste) ... 23

2.5.2 Mura(Inconsistency) ... 24

2.5.3 Muri (Irrationality) ... 25

2.6 Activity Relationship Chart (ARC) ... 26

2.7 Dimensionless Block Diagram ... 27

2.8 Cycle Time ... 28

(8)

2.10 Systematic Layout Planning ... 28

CHAPTER 3 – RESEARCH METHODOLOGY ... 29

3.1 Introduction ... 29

3.2 Problem Identification ... 29

3.3 Company Overview ... 29

3.4 Systematic Layout Planning ... 30

3.5 Background Theory ... 32

3.5.1 Facility Planning ... 32

3.5.2 Warehouse Layout ... 33

3.5.3 Warehouse Processes ... 33

3.6 Demand Forecast ... 39

3.7 Thesis Methodology ... 40

3.7.1 Preliminary Study ... 40

3.8 Software and Tools ... 43

CHAPTER 4 – RESULTS AND DISCUSSIONS ... 44

4.1 Research Object ... 44

4.2 Passenger Car Lead Time ... 46

4.3 Current Warehouse Flow Process Chart ... 48

4.4 Current Warehouse Layout ... 50

4.5 Warehouse Proposed Process ... 52

4.6 Warehouse Proposed Layout ... 55

4.7 Warehouse Capacity Analysis... 58

4.8 Unpacking Calculation ... 60

4.9 Proposed Man Power ... 61

4.10 Simulation ... 62

4.11 Process Guidelines ... 63

4.12 Concluding Remarks ... 76

CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 77

5.1 Conclusions ... 77

5.2 Recommendations ... 78

GLOSSARY ... 79

REFERENCES ... 80

APPENDIX A ... 81

CURRICULUM VITAE ... 83