Ukurta Tarigan, Meilita Tryana Sembiring, Indah Rizkya Tarigan, Khalida Syahpturi

Increasing Production Productivity by Improving Facility Layout Using the BLOCPLAN Method, Systematic Layout Planning, and Differential Evolution Algorithm

Introduction

Increasing production productivity by improving facility layout using the blocplan method, systematic layout planning, and differential evolution algorithm. Improve furniture production productivity by optimizing facility layout using BLOCPLAN, SLP, and Differential Evolution. Minimize material handling costs & distance, achieving 81.94% efficiency.

Abstract

A furniture company that produces dining chairs, coffee tables, and sofa has a common problem, namely the company's inability to complete production targets within the specified time period. These general problems are the result of less efficient production paths because there is backtracking, by-passing, cross movement, and material transfer between stations that are far apart. This problem can be resolved by using improvements to the production floor layout using BLOCPLAN, Systematic Layout Planning, and Algorithms Differential Evolution. This research aims to design a production floor layout that can minimize distance, total movement moment, and material handling costs, with a line efficiency rate above 75%. The results of this research show that the proposed layout was selected using the Differential Evolution Algorithm with a displacement distance of 231.24 meters, a total displacement moment of 15,820.93 meters/month, material handling costs of IDR 1,865,920/month, and a line efficiency rate of 81.94 %.

Review

This paper addresses a pervasive industrial challenge: the inability of manufacturing firms to meet production targets due to suboptimal facility layouts. Focusing on a furniture company producing dining chairs, coffee tables, and sofas, the abstract succinctly outlines the core problem stemming from inefficient material flow, characterized by backtracking, bypassing, cross-movement, and excessive transfer distances between stations. This clearly establishes the practical relevance of the research, positioning it as an effort to directly enhance production productivity and operational efficiency through strategic layout improvement, which is a critical area for competitive manufacturing. The methodological approach combines established techniques with a modern optimization algorithm. The integration of BLOCPLAN and Systematic Layout Planning (SLP) provides a structured framework for initial layout development and analysis, while the Differential Evolution Algorithm (DEA) is introduced as the mechanism for fine-tuning and selecting the optimal layout. This hybrid approach is commendable, leveraging the strengths of both qualitative/systematic planning and quantitative metaheuristic optimization to tackle the complex, multi-criteria problem of facility layout. The research clearly articulates its objectives: minimizing displacement distance, total movement moment, and material handling costs, while simultaneously targeting a line efficiency rate exceeding 75%. The results presented in the abstract demonstrate the efficacy of the proposed layout. The selected layout, derived from the Differential Evolution Algorithm, significantly reduces displacement distance to 231.24 meters, total displacement moment to 15,820.93 meters/month, and material handling costs to IDR 1,865,920/month. Crucially, it achieves a line efficiency rate of 81.94%, comfortably surpassing the target of 75%. These quantitative improvements strongly suggest that the methodology successfully resolves the initial problems of inefficient production paths, offering a tangible solution for increasing productivity and potentially enabling the company to meet its production targets within the specified timeframes. The paper thus offers a valuable case study and a practical demonstration of an integrated approach to facility layout optimization.

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