Relayout planning to reduce waste in food industry through simulation approach

Abstract

A good layout can streamline transportation within the factory, it contributes to lower cost and delivery time. This research is based on the case in a food company in Indonesia. This company produces snack. The characteristic of this production process is made to stock system with 24-working hours. From the observation of the production process, it indicates that layout planning is ineffective. This showed on long distance to move design items, a high number of worker and low throughput as well. The aim of this research is to re-layout in order to improve throughput and also reduce the number of workers and the distance. A conceptual model was developed to determine factors and responses of the system. Three scenario layouts were developed by using MULTIPLE methods. These scenario layouts were then translated and analyzed into operational models using the ProModel 6.0 Simulation Software. The results indicate an improvement of throughput by 15% for scenario 1, 28% for scenario 2, 21% for scenario 3. And for the number of workers reduce 13% for scenario 1, 2, and 3. For the over distance reduce 83% for scenario 1, 87% for scenario 2, 86% for scenario 3. Generally, scenario 2 give the largest improvement than other although need more expensive cost investment.