Facility layout design improvement in bottled drinking water at teaching factory

The Bottled Drinking Water Teaching Factory (Tefa) at State Polytechnic of Jember (Polije) produces mineral water packaged in several sizes of bottles, glasses, and gallons. The efficiency and effectiveness of the bottled drinking water production process is influenced by the layout of production facilities. The mismatch of machine layout arrangement and the number of unused equipment causes material flow to be longer. This study aims to redesign the layout of the Tefa Bottled Drinking Water facility to maximize area utilization and reduce empty space. This research provides recommendations for facility layout improvements using the Systematic layout planning (SLP) method. Alternative designs were proposed and compared the performance of each design with the initial layout. The results of the proposed method’s distance processing affect the total material handling cost. The total distance of the proposed method facility is 11.7 meters while the distance of the current facility is 28.8 meters so that can save material handling costs by 59%.


Introduction
Facility layout design is one of the factors that affect company performance.Facility layout design supports the successful flow of efficient production activities.Today, bottled water companies face increasingly difficult challenges, where to remain competitive they must improve their efficiency.The effort that can be made is that the company must become reliable by providing high quality products and low production costs [1].Furthermore, this can be accomplished through raising worker productivity, facility layout and space usage, as well as work standards [2].The efficiency of the company's layout and productivity have a mutual influence on the overall performance and quality of the company.
The arrangement of physical components, such as machinery and equipment, in a facility to maximize material flow while minimizing costs is known as facility layout [3].Significant improvements in facility layout can be made by reducing the distance and time of material movement from one work station to another [4].Consequently, lower production costs will result from efficient work flow in the production process.These factors make facility layout design a top concern for the sector in an effort to boost output.
One industry that is important to implement facility layout design is bottled drinking water.Tefa bottled drinking water Polije is a teaching factory that processes drinking water into bottled drinking water products.The packaging used consists of 3 types, namely 220 ml glass packaging, 600 ml bottles, and 9 liter gallons.The production capacity of Tefa Polije in one process is 4000 liters with the production of 18,182 glass packages.Glass packaging will be secondary packaged using cartons.One cardboard package contains 48 pieces, so that in one production, 378 cardboard packages are produced.The selling price of cardboard packaging is IDR 15,000.The total revenue in one production reached Rp. 5,681,818.This income is relatively high, but in practice production activities are not carried out continuously.Production activities are only carried out twice a week with a capacity of less than 4000 liters.This is due to the limited product warehouse and production space that has not been utilized effectively so that there is still a lot of space that has not been utilized as its function.The total distance between facilities is currently approximately 28 meters with a total production time of bottled water for 3 hours.As a result, the revenue generated by Tefa AMDK Polije is less than optimal.The urgency of this research lies in improving the layout of facilities so as to shorten the distance between facilities and production time.
The role of layout design to realize the sustainability of Tefa Polije bottled water is very important.Facility layout design involves long-term decision-making with changes potentially resulting in high adjustment costs.A good layout will have an impact on environmental industry performance [5].Layout design significantly affects efficiency in the production line which is an important factor in productivity [2].The concept of effective layout focuses on optimal utilization of production floor space to improve space quality and reduce material movement costs [1].Therefore, in designing a layout, all influential factors must be carefully taken into account.
This research aims to redesign the production facility based on the distance of material movement, and material handling costs.The research method used is Systematic layout planning (SLP).The SLP method in layout design has been widely used by researchers to improve productivity and space utilization in production units [1], [5], [6].The SLP method is expected to provide a good alternative layout of the proposed facility.

Research methods
This research was conducted at Tefa Polije bottled drinking water from June to September.The research data sources were obtained from interviews, measurements, and direct observations at Tefa Polije bottled drinking water.Measurements made include the distance traveled between equipment and material handling costs.Material handling distance is calculated using the Euclidean method approach.Euclidean distance is the distance measured straight between the center of one facility and the center of another facility [7].The Euclidean distance provides a description of the shortest distance between two points, serving as the lower limit for the actual distance measurement [8].To calculate the Euclidean distance of one facility with another facility using the following formula: Where: dij = distance between facility centers I and j yi = y-coordinate at facility center i xi = x coordinate at facility center i Time measurement is calculated based on the flow of materials from one facility to another using a timer.The formula used to calculate material handling costs is as follows [7].

∑ ∑
where: r = distance of material handling f = frequency of material handling Material handling costs are the costs required during material transfer activities.To calculate the total material handling cost required is the cost of material handling per meter, where the cost has been calculated regarding the cost of machine maintenance, worker wages, and machine depreciation.To determine the value of material handling costs is based on the company's policies and capabilities with the provisions of material handling costs per meter.
This study provides recommendations for improving the layout of facilities using the Systematic layout planning (SLP) method.SLP, which is a layout design method with respect to material flow or production sequence.The first step is to identify material flow, distance and time from one facility to another.The second stage is to calculate the total cost of existing material handling.The third stage is to create a relationship or linkage of ARC.The fourth stage is to design a proposed facility layout improvement.The last stage is to evaluate the total material handling cost of the proposed layout that considers the distance of material movement.

Result and discussion
Layout design analysis using the SLP method can be used for companies that have ineffective and inefficient facility layouts.The results of the analysis of the layout of the Tefa facility for bottled drinking water in Polije are as follows:

Determination of current material handling distance
The Tefa Polije production process begins with the stage of receiving raw material water from the tank truck, then accommodated in the raw material water tank, then enters the filter consisting of carbon, manganese, and spun, after that enters the clean water reservoir which will pass through the sponge filter, RO, Ozone, Ozone mixer, and ready-to-drink bottled water is stored in the bottled water tank.After that, AMDK before being packaged will pass through the filter again.Finally, bottled water is packed using cardboard boxes in the packaging room.Material handling distances between departments at Tefa Polije can currently be seen in Table 1.The frequency of material handling flow between facilities is once and the total distance of material handling that occurs is 28.8 meters.With the following details from the raw material tank truck to the raw material water reservoir is 10.1 meters, from the reservoir to the filter is 0.3 meters, from the filter to the clean water reservoir is 0.3 etc. Good facility layout planning determines efficiency and maintains the survival of an industry [9].The impact of unplanned layout design and improper material movement distance causes problems such as decreased production and increased costs incurred [7].

Tabel 1. Current material handling distance
Material handling distance will affect the total cost of material handling.Material handling costs stem from activities involving the movement of materials, either between machines or across different departments within a facility.The unit used in material handling costs is Rupiah / meter [10].To find out the cost of material handling, it is necessary to know the details of each material handling cost.Details of material handling costs are used as follows:  The production layout that has been applied to Tefa Polije AMDK results in material handling costs for glass packaging of Rp 2,344 / meter.Improvements will be made by providing a proposed layout that has a shorter total displacement distance so as to minimize the material handling costs that will be incurred [11].Material handling costs from one department to another can be seen in Table 1.Therefore, the main step for factory layout improvement should start with identifying the problems of the current factory layout to maximize productivity with minimal investment.

Activity relationship chart (ARC)
The ARC is derived from facility data, establishing connections to assess the proximity between two facilities.The evaluation of proximity considers various factors, such as the interconnection of production processes, material flow, equipment utilization, human interactions, and other relevant aspects [12], [13].In this study, the reasons for the linkages used and the degrees of freedom are in Table 2.
The ARC, depicted as a rhombus in an activity linkage map, comprises two components.The upper section illustrates symbols indicating the degree of association between two departments or rooms.Meanwhile, the lower part articulates the rationale employed to quantify the extent of this relationship [14].Based on the degree of relationship between activities and the reasons, the facility linkage relationship map (ARC) for 11 facilities at Tefa Polije is shown in Figure 1.The ARC illustrates the relationships between pairs of existing facilities, each marked with degrees of proximity represented by the letters A, E, I, O, U, and X.Additionally, the reasons for their proximity are delineated.Data from the Activity Relationship Chart (ARC) is used for planning and analyzing activity relationships between departments, the results of which are utilized for the location of each Department [15].

Current and proposed layout
Tefa Polije's proposed layout design considers several things, namely:  Separate the raw material warehouse storage area and the finished material storage area to minimize material distance. Movement in the workplace layout and movement in materials and equipment must be placed at a distance that is easily accessible. The finished material storage area is placed close to the packing table and exit.
 Proposed layout improvements affect the time and speed of packaging preparation.In this case, the time required during packaging preparation will be less than the initial layout.The results of the current layout can be seen in Figure 2 and the proposed facility layout can be seen in Figure 3.

Total Material Handling Cost Proposed
The results of the proposed method's distance processing affect the total material handling cost.The results of data processing obtained the total distance of the proposed method of 11.7 meters while the current drinking water distance is 28.8 meters.The difference is because the raw material room to filling is carried out sequentially, and the filling and packing process is carried out in one location so that it is closer and reduces costs.Measurement of total material handling costs refers to the current Tefa conditions with respect to the layout of facilities and production flow of the current layout conditions.The calculation of total material handling costs obtained from the results of distance covered, frequency, and material handling costs can be seen in Table 3. Table 3 shows that the proposed method compared to the current conditions in the company is more effective because it is able to reduce material handling costs.Accurate measurement of material handling is crucial, as the results obtained have led to a significant reduction of 59% in the distance of the facility layout for materials and a substantial cost savings of 69% in material handling.In addition, the material flow aspect is an aspect that affects the layout of the work area which has an impact on the level of efficiency and productivity of the production process [16].In addition, the material flow aspect is an influential aspect in developing work area layouts that have an impact on the level of efficiency and productivity of the production process [3].

Conclusion
The results of the proposed method's distance processing affect the total material handling cost.The total distance of the proposed method facility is 11.7 meters while the distance of the current facility is 28.8 meters.This means that the distance between facilities can be streamlined by 59%.This will affect the total material handling, namely with the current facility layout of Rp. 67,500 and the proposed facility layout of Rp. 20,861 so that it can save 69%.

Table 2 .
The reasons for the linkages used and the degrees of freedom

Table 3 .
Total material handling cost proposed