Universitas Stikubank (UNISBANK) Semarang

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 Learning Objectives
When you complete this chapter, you should be able to :

Identify or Define:

• Fixed-position layout
• Office layout
• Retail layout
• Warehouse layout
• Process-oriented layout
• Product-oriented layout
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 Learning Objectives

When you complete this chapter, you should be able to :

Describe or explain:
• How to achieve a good layout for the process facility
• How to balance production flow in a repetitive or
product-oriented facility

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WHY ARE Layouts important

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 CONTOH-1 : Innovation at
McDonald’s
 Indoor seating (1950’s)
 Drive-through window (1970s)
 Adding breakfast to the menu (1980s)
 Adding play areas (1990s)
 New kitchen (made for you) (1990s)
 Self service kiosk (2004s)
 Indoor seating: linger, grab and go, flexible
(six out of the seven are layout decisions)
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 McDonald’s - New Kitchen
Layout
Fifth major innovation - kitchen design
• Elimination of some steps, shortening of others
• New bun toasting machine (11 seconds vs 30 seconds)
• Repositioning condiment containers (one motion, not two)
• Sandwiches assembled in order
• Production levels controlled by computer
• Discard only meat when sandwiches do not sell fast enough
• Savings of $100,000,000 per year in food costs

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 Innovation at McDonald’s - kitchen design

Dapur yang telah dirancang ulang di McDonald’s Manhattan. Tata letak yang lebih efisien
membutuhkan tenaga kerja yang lebih sedikit, mengurangi sampah, dan menyediakan pelayanan
yang lebih cepat. 2-7
 Innovation at McDonald’s-self service kiosk

McDonald’s mengetahui kios mengurangi kebutuhan ruang dan waktu tunggu.

Pemenuhan pesananan menjadi lebih cepat. Pelanggan menyukainya. Penjualan naik
10%-15%. 2-8
 Innovation at McDonald’s
indoor seating: zona “diam” (linger)

Kursi dan sofa yang nyaman ditambah koneksi Wi-Fi membuat zona ini
menarik bagi mereka yang ingin nongkrong dan bersosialisasi.
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 Innovation at McDonald’s
indoor seating: zona “ambil dan pergi” (grab and go)

Zona ini memiliki tempat duduk yang tinggi dengan bangku ala bar bagi
pelanggan yang makan sendirian. TV plasma menemani mereka.

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 Innovation at McDonald’s
indoor seating: zona “fleksibel” (flexible)

Zona ini berisi kursi empuk dari tenunan yang berwarna cerah, membuat zona
ini cocok untuk keluarga dan kelompok besar. Meja dan kursi dapat dipindah-
pindah.
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 CONTOH-2
Bandara Internasional Pittsburg

Terminal bandara internasional Pittsburg berbentuk

huruf X dan jalur pendaratan pesawatnya ada 2.

Hal tsb menyebabkan keterlambatan penerbangan

berkurang, penumpang pesawat lebih merasa
nyaman, biaya bahan bakar menurun, dan kota
menjadi pusat dan lokasi bisnis/konferensi yang
lebih menarik.

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 CONTOH-3
Toko Wal-Mart di Rogers, Arkansas
Dengan lorong-lorong yang lebar, etalase yang
terbuka, dan wilayah di mana pelanggan dapat
duduk beristirahat, serta rak-rak pakaian yang
elegan.

Wal-Mart yang baru ini kelihatan seperti toko

swalayan kelas atas dan membentuk
kecenderungan untuk belanja lebih banyak dan
lebih lama.
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 CONTOH-4
Kamar Mandi Denver’s Convention Center
Tata letak yang kreatif telah membantu
pembentukan “gap jamban” dengan memasang
dinding yang dapat dipindah-pindahkan, agar dapat
mengakomodasi rasio wanita-pria yang berbeda-
beda antara konvensi yang satu dengan lainnya.

Fleksibilitas ini meningkatkan kemampuan Denver’s

Convention Center unt memasarkan pelayanannya.
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 CONTOH-5
Supermarket Kroger, Memphis
Tata letak toko Kroger mencakup restoran siap saji, laboratorium foto, toko
video, bahan-bahan makanan, dan peralatan rumah tangga, serta obat-
obatan.

Tata letak toko ini juga meliputi cabang bank NBC yang memberikan
pinjaman dan menangani semua kebutuhan perbankan pelanggan.

Pendekatan tata letak ini membuat supermarket tsb menjadi tempat

belanja one stop shopping yang menarik.

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 Layouts are very important

• Layouts are found in every area of a business because

every facility has a layout.

• Good layouts can improve coordination across

departmental lines and functional area boundaries.

• Each process in a facility has a layout that should be

carefully designed.

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 What is Facility Layout

• Location or arrangement of everything within &

around buildings

• Objectives are to maximize

• Customer satisfaction
• Utilization of space, equipment, & people
• Efficient flow of information, material, & people
• Employee morale & safety

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 Strategic Importance of
Layout
Proper layout enables:

• Higher utilization of space, equipment,and people

• Improved flow of information, materials, or people
• Improved employee morale and safer working
conditions
• Improved customer/client interaction
• Improves customer/client satisfaction
• Flexibility
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 Six Layout Strategies

• Fixed-position layout
• large bulky projects such as ships and buildings
• Office layout
• positions workers, their equipment, and spaces/offices
to provide for movement of information
• Retail/service layout
• allocates shelf space and responds to customer
behavior
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 Six Layout Strategies -
continued
• Warehouse layout
• addresses trade-offs between space and material
handling
• Process-oriented layout
• deals with low-volume, high-variety production
(“job shop”, intermittent production)
• Product-oriented layout
• seeks the best personnel and machine use in
repetitive or continuous production

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 Layout Strategies
Project Job Shop Office Retail Warehouse Repetitive
(fixed-position) (Process- (storage) /Continuous
oriented) (product-
oriented)
Examples
Ingal Ship Shouldice Allstate Kroger’s Federal-Mogul’s Sony’s TV
Building Corp. Hospital Insurance Supermarket Warehouse Assembly Line

Trump Plaza Olive Microsoft Walgreens The Gap’s Dodge

Garden distribution center Caravans
Bloomingdales
Minivans
Pittsburgh
Airport

Problem
Move material Manage varied Locate workers Expose Balance low- Equalize the
to the limited material flow for requiring customer to cost storage task time at
storage areas each product frequent contact high-margin with low-cost each
around the site close to each items material workstation
other handling

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 Requirements of a Good Layout
 an understanding of capacity and space requirements
 selection of appropriate material handling equipment
 decisions regarding environment and aesthetics
 identification and understanding of the requirements
for information flow
 identification of the cost of moving between the
various work areas

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 Constraints on Layout
Objectives
• Product design & volume
• Process equipment & capacity
• Quality of work life
• Building and site

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 Fixed-Position Layout

• Design is for stationary project

• Workers and equipment come to site
• Complicating factors
• Limited space at site
• Changing material needs

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 Factors Complicating a Fixed Position Layout

• There is limited space at virtually all sites

• At different stages in the construction process,
different materials are needed – therefore,
different items become critical as the project
develops
• The volume of materials needed is dynamic

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TATA LETAK PADA POSISI TETAP PADA
PEMBUATAN KAPAL

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 Pada ruang operasi, pasien tetap diam di meja operasi, sementara
personel medis dan peralatan dibawa ke lokasi operasi (ruang operasi)

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Pembangunan sebuah rumah dikerjakan di tempat dengan peralatan,
bahan, dan pekerja yang dibawa ke lokasi.

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 Office Layout
¨ Design positions people, equipment, & offices
for maximum information flow
¨ Arranged by process or product
¨ Example: Payroll dept. is by process
¨ Relationship chart used
¨ Examples
¨ Insurance company
¨ Software company

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 Office Layout Floor
Plan

Accounting
Finance
Fin. Acct.

Manager Brand X

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 Relationship Chart

Ordinary
1
1 President 2 closeness:
O President (1) &
3 Costing (2)
2 Costing U 4
A A
3 Engineering I
O Absolutely
necessary:
4 President’s Secretary President (1) &
Secretary (4)
I = Important
U = Unimportant

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 Office Relationship Chart
1 President
2 Chief Technology Officer O Val. Closeness
U
A A A Absolutely
3 Engineer’s Area I I necessary
O I I
4 Secretary I I U E Especially
A I O O
5 Office entrance A E U O important
X E E U
U A O I Important
7 Equipment cabinet O U
O I O Ordinary OK
8 Photocopy equipment X
U A
E U Unimportant
9 Storage room E
X Not desirable
10 Storage room

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Kantor terbuka ini menawarkan ruang bersama yang besar yang
mendorong para pekerja untuk berinteraksi.

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 Retail / Service Layout

¨ Design maximizes product exposure to customers

¨ Decision variables
¨ Store flow pattern
¨ Allocation of (shelf) space to products
¨ Types
¨ Grid design Video
¨ Free-flow design

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 Retail /Service Layout - Grid
Design
Grocery Store
Bread Meat

Produce Frozen Foods

Milk

Check-
Office Carts
out

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Retail/Service Layout - Free-Flow Design
Apparel Store

Feature Trans.
Counter

Display Table

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Store Layout-with Dairy, Bread, High Drawer Items in
Corners

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 Di toko El Eajon, California, Wal Mart melatih pegawainya untuk membantu
pembeli yang kebingungan oleh alat di sebelah tangga berjalan yang membawa
keranjang belanja dari lantai ke lantai.

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 Retail Layouts - Some Rules of
Thumb
• Locate high-draw items around the periphery of the store
• Use prominent locations such as the first or last aisle for
high-impulse and high margin items
• Remove crossover aisles that allow customers the
opportunity to move between aisles
• Distribute what are known in the trade as “power items”
(items that may dominate a shopping trip) to both sides of
an aisle, and disperse them to increase the viewing of other
items
• Use end aisle locations because they have a very high
exposure rate
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 A Good Service Layout (Servicescape)
Considers
• Ambient conditions
- background characteristics such as lighting, sound,
smell, and temperature.
• Spatial layout and functionality
- which involve customer circulation path planning
• Signs, Symbols, and Artifacts
- characteristics of building design that carry social
significance
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 Warehouse Layout
¨ Design balances space (cube) utilization & handling
cost
¨ Similar to process layout
¨ Items moved between dock & various storage
areas
¨ Optimum layout depends on
¨Variety of items stored
¨Number of items picked

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 Warehouse Layout Floor
Plan
Conveyor
Truck

Zones Order Picker

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 Cross Docking
¨ Transferring goods In-
¨ from incoming trucks at receiving coming
docks Outgoing
¨ to outgoing trucks at shipping docks

¨ Avoids placing goods into storage

¨ Requires suppliers provide
effective addressing (bar codes)
and packaging that provides for
rapid transhipment

© 1984-1994 T/Maker Co.

© 1995 Corel Corp.

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 CROSS
DOCKING
 Random Stocking Systems Often:
• Maintain a list of “open” locations
• Maintain accurate records of existing inventory
and its locations
• Sequence items on orders to minimize travel time
required to pick orders
• Combine orders to reduce picking time
• Assign certain items or classes of items, such as
high usage items, to particular warehouse areas so
that distance traveled is minimized
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 Warehouse Layouts - Out-and-back Pattern
Tata letak gudang yang paling mendasar adalah out-and-back pattern. Nomor-
nomor menunjukkan tempat penyimpanan untuk item yang sama atau mirip.

Storage area

3 5 5 6 4 2 7

Dock Aisle

1 5 5 4 4 2 7

Storage area

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 Warehouse Layouts - Zone System

Zones Zones Control

station Shipping

Click to add title doors

Tractor
trailer

Tractor
trailer
Feeder Feeder
lines lines Overflow

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Garasi parkir di Wolfsburg, Jerman, ini hanya memakan tempat 20% dari
ruang garasi biasa. Dengan garasi ini mobil diambil lebih cepat, tanpa mobilnya
rusak oleh petugas.

Pada parkir garasi di Wolfsburg, Jerman menunjukkan bahwa bentuk

automated storage and2-48
retrieval system (ASRS) beragam
TERIMA KASIH