PLANT LAYOUT COMPARATIVE ANALYSIS: A CASE STUDY OF CARTON PRODUCT

Abstract

This research aims to investigate and compare the layout of a carton manufacturing plant in the production process to increase productivity, reduce production costs, and minimize the movement time of workers and materials. The study utilizes the Systematic Layout Planning (SLP) method, starting by identifying issues through an experiment (4M) such as Methods, Machinery, Man, and Materials to understand their compatibility and the characteristics of the production process. The subsequent steps involve studying the paper box manufacturing process by analyzing the time and distance used in production. Subsequently, the research applies the SLP method, using Flow Process Charts and Relationship Charts, to design a new plant layout. This layout is then compared with the existing one. The relationship and mutual benefits between each department, which in the traditional layout lacked design based on proper facility layout principles, resulted in adjacent departments that might not have any relationship. However, the newly designed layout ensures that adjacent departments can mutually benefit from one another. In the traditional layout, the distance was 42.99 meters, while the proposed layout reduced the distance to 40.04 meters, representing a 6.86 percent reduction. Regarding time, the traditional layout required 143.846 seconds, whereas the proposed layout reduced the time to 126.189 seconds, a 12.27 percent decrease.