Usulan Perbaikan Tata Letak Fasilitas pada PT. Asia Raya Foundry Menggunakan Metode Value Stream Mapping dan Metode Grafik

Abstract

PT. Asia Raya Foundry is a manufacturing company engaged in metal casting, particularly in the production of screw press components. However, the production process has not been running efficiently due to issues in the facility layout and production flow, such as backtracking, by-passing, and excessively long distances between workstations. This study aims to design an improved facility layout and production flow that is more efficient, in order to reduce waste and increase productivity. The methods used in this study are Value Stream Mapping (VSM) to identify waste activities in the production flow, and a graph-based method utilizing the from-to chart to design a proposed layout based on the weight and frequency of material transfers between workstations. The analysis results indicate that Non-Value Added (NVA) activities are quite dominant, with a waiting time of 125.45 hours out of a total production time of 212.7 hours. The most significant waste occurred at the moulding and fettling stations, which were resolved through batch size adjustments and rescheduling. The proposed layout successfully reduced the total transfer moment from 49,784.69 m/month to 30,719.62 m/month. In addition, the Line Efficiency Rate (LER) increased significantly from 58.6% to 95.23%, indicating a substantial improvement in efficiency. Therefore, the proposed improvements in this study have successfully optimized the material flow and facility layout at PT. Asia Raya Foundry.