PERANCANGAN TATA LETAK FASILITAS

I. Pengertian Pabrik

        Pabrik adalah tempat dimana faktor manusia, peralatan fasilitas produksi, material, energi, uang, informasi dan sumber daya alam (air, tanah, mineral dll) dikelola bersama-sama dalam suatu sistem produksi guna menghasilkan suatu produk atau jasa secara efektif, efisien dan aman. 

II. Pabrik Vs Industri 

1. Industri > Pabrik 
2. Berdasarkan aktivitasnya: primary raw-material industries, manufacturing industries, distribution industries, service industries. 
3. Producers-goods industries Consumer-goods industries 
4. Pabrik terutama untuk industri yang menghasilkan produk jadi (finished good). 

III. Macam-macam Proses Manufaktur 

1. Continuous Process Industry (24 hours) 
2. Repetitive Process Industry (mass production) 
3. Intermitten Process Industry (job order) 

IV. Dasar-dasar Perancangan Pabrik 

1. Plant Design vs Plant Layout 
2. Plant Design: Modal, product’s design (aspek fungsi dan kemudahan pembuatan), sales volume, tool engineering, make or buy analysis, plant size, plant location, plant layout, type of building, product diversification, price of product, organization development (the overall design of enterprise) 
3. Plant Layout: perencanaan fasilitas guna berlangsungnya proses secara optimal 

V. Prosedur Plant Design 

1. Riset pasar dan peramalan penjualan 
2. Management policies 
3. Product design 
4. Process and operation design 
5. Plant location and layout 
6. Costs analysis 
7. Finance 
8. Project realization 
9. Manufacturing process 
10. Output distribution 

VI. Plant Design

a. Facilities Location: 

    customers-suppliers interaction

b. Facilities Design: 

1. Structural design: jaringan listrik, air, gas, penerangan dll 
2. facilities lay-out design: etak mesin, peralatan
3. material handling design: sistem pemindahan material.

VII. Aspek perhatian merancang bangunan pabrik 

1. Desain bangunan dan konstruksinya, 
2. Jarak bentangan dan kolom, 
3. Lantai, 
4. Dinding dan jendela, 
5. Atap dan langit-langit, 
6. Bangunan satu tingkat atau banyak. 

VIII. Prinsip-prinsip dasar Plant Layout 

1. Whole Integrated, 
2. Minimum distance of movement, 
3. Good flow of process, (Back-tracking, cross-movement, congestion), 
4. Effectively space used, 
5. Satisfying and safe for workers, 
6. Flexibility layout. 

IX. Keuntungan tata letak yang baik: 

1. Increase output, 
2. Decrease delay, 
3. Decrease Material Handling (30-90%), 
4. Space efficiency, 
5. Optimum resources, 
6. Decrease Inventory in-process 
7. Time efficiency, 
8. Decrease healt and safety risk, 
9. Upgrade Attitude and labour satisfaction, 
10. Good supervision, 
11. Decrease intersection, 
12. increase quality of product.

X. Tahapan Plan Layout 

1. Analisa produk, 
2. Analisa proses, 
3. Sigi dan Analisa pasar, 
4. Analisis macam dan jumlah peralatan dan kebutuhan luas area, 
5. Kembangkan alternatif layout, 
6. Perancangan. 

Literature

Plant Layout and Material Handling, James M Apple, Jhon Wiley & Sons Inc, New York, 1977

Facility Layout and Location, an Analytical Approach, Francis R.L, Prentice Hall Inc, Englewood Cliffs, New Jersey, 1974

Facilities Design, Heragu S, PWS Publishing Company, Boston, 1997

Factory Planning and Plant Layout, Ireson W.G, Englewood Cliffs, New Jersey, 1952

Plant Layout and Material Handling, Meyers F.E, Prentice Hall, Englewood Cliffs, New Jersey, 1993

Plant Layout and Design, Moore J.M, Macmillan Publishing Co.Inc, New York, 1962

Facilities Planning, Tompkins J.A, Jhon Wiley & Sons Inc, New York, 1996

Tata Letak Pabrik dan Pemindahan Bahan, Wignjosoebroto S, Guna Widya, Jakarta, 1992

Perencanaan & Perancangan Fasilitas, Purnomo H, Graha Ilmu, Yogyakarta, 2004

Materi Kuliah Perancangan Tata Letak Fasilitas. Indrayana Masrul. UWMY. Yogyakarta. 2015