Kuliah-responsi Versi B TATA LETAK
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Transcript of Kuliah-responsi Versi B TATA LETAK
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To AccompanyKrajewski & Ritzman
Implementchanges
6
Redesign Process(Revise layout)
5
Redesigning a Process
Through Layout Revision
Documentprocess
3
Definescope
2
Evaluateperformance
4
Figure 7.1Figure 7.1
Identifyopportunity
1
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To AccompanyKrajewski & Ritzman
Absolute Locations
(a) Original layout(a) Original layout
Frozen
foodsDry
groceries
Bread Vegetables
Meats
Figure 7.2Figure 7.2
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To AccompanyKrajewski & Ritzman
Absolute Locations
(b) Revised layout(b) Revised layout
Frozen
foodsDry
groceries
BreadVegetables
Meats
Figure 7.2Figure 7.2
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To AccompanyKrajewski & Ritzman
Layout Types
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
(a) Layout of a job shop(a) Layout of a job shop
Figure 7.3Figure 7.3
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Layout Types
(b) Layout of a production line(b) Layout of a production line
Figure 7.3Figure 7.3
Station 1 Station 2 Station 3 Station 4
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To AccompanyKrajewski & Ritzman
Group Technology
Machine
1
Machine2
Machine
3
Machine
4Machine
5
Materials in
Finished
goods out
Figure 7.4Figure 7.4
One Worker, Multiple MachinesOne Worker, Multiple Machines
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To AccompanyKrajewski & Ritzman
Group Technology
Figure 7.5Figure 7.5
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and
shipping
L
L L
L L
L L
L
(a) Jumbled flows in a job shop without GT cells(a) Jumbled flows in a job shop without GT cells
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To AccompanyKrajewski & Ritzman
Group Technology
(b) Line flows in a job shop with three GT cells(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly
area
A A
L M DL
L MShipping
D
Receiving
G
Figure 7.5Figure 7.5
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To AccompanyKrajewski & Ritzman
Department Area Needed (ft2)
1. Administration 3,500
2. Social services 2,600
3. Institutions 2,400
4. Accounting 1,600
5. Education 1,500
6. Internal audit 3,400
Total 15,000
100'
150'
Office ofBudget
Management
3 6 4
1 2 5
Figure 7.6Figure 7.6
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To AccompanyKrajewski & Ritzman
Office ofBudget
ManagementTrips between Departments
Department 1 2 3 4 5 6
1. Administration
2. Social services
3. Institutions
4. Accounting
5. Education
6. Internal audit
3 6 5 6 10
8 1 1
3 9
2
1
100'
150'
3 6 4
1 2 5
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To AccompanyKrajewski & Ritzman
Office ofBudgetManagement
y Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6
100'
150'
3 6 4
1 2 5
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To AccompanyKrajewski & Ritzman
Office ofBudgetManagement
y Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 3
100'
150'
3 6 4
1 2 5
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To AccompanyKrajewski & Ritzman
Office ofBudgetManagement
y Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 32
4
100'
150'
3 6 4
1 2 5
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To AccompanyKrajewski & Ritzman
Office ofBudgetManagement
100'
150'
3 6 4
1 2 5
y Departments 1 and 6 close together
y Departments 3 and 5 close together
y Departments 2 and 3 close together
Figure 7.7Figure 7.7
100'
150'
1 5
6 32
4
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To AccompanyKrajewski & Ritzman
Out-and-Back Warehouse
Figure 7.10Figure 7.10
Dock Aisle
Storage area
Storage area
3 5 5 6 4 2 7
1 5 5 4 4 2 7
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To AccompanyKrajewski & Ritzman
Zone Systems
Figure 7.11Figure 7.11
Click to add title
Zones Zones Control
station Shipping
doors
Tractor
trailer
Tractor
trailer
Overflow
Feeder
linesFeeder
lines
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17
Design Product Layouts: Line
BalancingLine balancing is the process of assigning tasks to workstations
in such a way that the workstations have approximately the same
processing time requirements. This results in the minimized idle time
along the line and high utilization of labor and equipment.
Cycle time is the maximum time allowed at each workstation
to complete its set of tasks on a single unit
What is the cycle time for the system above?
Worker 1 Worker 2
4 tasks 2 tasks
Each task takes 1 minutes, how to balance?
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18
Parallel Workstations
1 min.2 min.1 min.1 min.30/hr. 30/hr. 30/hr. 30/hr.
1 min.
2 min.
1 min.1 min.60/hr.
30/hr. 30/hr.
60/hr.
2 min.
30/hr.30/hr.
Bottleneck
Parallel Workstations
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19
The obstacle
The difficulty to forming task bundles that have thesame duration.
The difference among the elemental task lengths
can not be overcome by grouping task. Ex: Can you split the tasks with task times {1,2,3,4} intotwo groups such that total task time in each group is thesame?
Ex: Try the above question with {1,2,2,4}
A required technological sequence prohibit thedesirable task combinations Ex: Let the task times be {1,2,3,4} but suppose that the
task with time 1 can only done after the task with time 4 iscompleted. Moreover task with time 3 can only done after
the task with time 2 is completed. How to group?
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20
Cycle time is the maximum time allowed at each
workstation to complete its tasks on a unit.
Cycle Time
The major determinant: cycle time
Minimum cycle time: longest task time by
assigning each task to a workstation
Maximum cycle time: sum of the task time by
assigning all tasks to a workstation
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21
Determine Maximum Output
Cycle Time: Time to process 1 unit
Example: If a student can answer a multiple choice question in 2 minutes
but gets a test with 30 questions and is given only 30 minutes then
OT=30 minutes; D=30
Desired cycle time=1 minute < 2 minutes = Cycle time from the processcapability
OT
D
OT
D
CT
OT
DCT
OT
D
CT
:
:
OperatingTimePerDay
DesiredOutputRate
DesiredCycleTime
CycleTime FromProcessDesign
Can produce at the desired level, design is feasible
Cannot produce at the desired level, design is infeasible
!
! n
u
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22
Determine the Minimum Number
of Workstations Required: Efficiency
stask timeofsum=t
CTt
productafortimeAvailabaleproductafortask timeTotal
OT/DtN
OT
t)(D)(
dayaintimeAvailabale
dayainproducedproductsallfortask timeTotal=N
min
min
!!!
!
Example: Students can answer a multiple choice question in 2 minutes but
given a test with 30 questions and is given only 30 minutes. What is the
minimum number of students to collaborate to answer all the questions in
the exam?
Total operation (task) time = 60 minutes = 30 x 2 minutes
Operating time=30 minutes60/3=2 students must collaborate. This Nmin below.
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24
Example 1: Precedence Diagram
Precedence diagram: Tool used in line balancing
to display elemental tasks and sequence
requirements
a b
c d e
0.1 min.
0.7 min.
1.0 min.
0.5 min. 0.2 min.
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25
Example 1: Assembly Line
Balancing
Arrange tasks shown in the previous slideinto workstations.
Use a cycle time of 1.0 minute Every 1 minute, 1 unit must be completed
Rule: Assign tasks in order of the most numberof followers
If you are to choose between a and c, choose a
If you are to choose between b and d, choose b
Number of followers: a:3, b:2, c:2, d:1, e:0
Eligible task fits into the remaining time and allof its predecessors are assigned.
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26
o u on o xamp e .
Assigning operations by the number
of followersWork-Station
TimeRemaining Eligible
AssignTask
StationIdle Time
1 1.0.9
.2
a,cc
none
ac
- .22 1.0
0b
noneb- 0
3 1.0.5
.3
de
-
de
- .3.5
- Eligible operation fits into the remaining time and its predecessors are already
assigned.- What is the minimum cycle time possible for this example?
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28
Line Balancing Heuristic Rules
Assign tasks in order of most following
tasks.
Assign task in the order of the greatest tasktime.
Assign tasks in order of greatest positional
weight.
Positional weight is the sum of each tasks
time and the times of all following tasks.
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29
Solution to Example 1. Assigning
operations using their task times.Wor -
t tion
i
ining ligi l
ign t tion
I l i1 1.
.9
.2
a,ca
none
ca
- .22 1.
none -1...
e-
e- .
.
Eligible operation fits into the remaining time and its predecessors are already
assigned.
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30
Positional Weights
Assign tasks in order of greatest positional weight.
Positional weight is the sum of each tasks time
and the times of all following tasks.
a:1.8 mins; b: 1.7 mins; c:1.4 mins; d: 0.7 mins;
e:0.2 mins.
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31
Solution to Example 1. Assigning
operations using their task times.Wor -
t tion
i
ining ligi l
ign t tion
I l i1 1.
.
.
a,cc
none
ac
- .1.
none -3 1.
.
.3e-
e- .3
.
Eligible operation fits into the remaining time and its predecessors are already
assigned.
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32
c d
a b e
f g h
0.2 0.2 0.3
0.8 0.6
1.0 0.4 0.3
Example 2
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33
Station 1 Station 2 Station 3 Station 4
a b e
f
d
g h
c
Solution to Example 2
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Line Balancing
Green Grass, Inc.Green Grass, Inc.
Big BroadcasterBig Broadcaster
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Line Balancing Big BroadcasterBig Broadcaster
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AA
DD Attach agitatorAttach agitator 4040 BB
EE Attach drive wheelAttach drive wheel 66 BB
FF Attach free wheelAttach free wheel 2525 CC
GG Mount lower postMount lower post 1515 CC
HH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, EII Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
3030
B
A
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, EII Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
5050
B
C
A
3030
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, EII Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
5050
3030
4040
D
B
C
A
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
5050
E3030
4040
D
B
C
A
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
5050
E3030
2525
4040
D
B
F
C
A
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
5050
1515
E3030
2525
4040
D
B
F
C
A
G
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
2020
5050
1515
E3030
2525
4040H
D
B
F
C
A
G
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
AA Bolt leg frame to hopper Bolt leg frame to hopper 4040 NoneNone
BB Insert impeller shaftInsert impeller shaft 3030 AACC Attach axleAttach axle 5050 AADD Attach agitatorAttach agitator 4040 BBEE Attach drive wheelAttach drive wheel 66 BBFF Attach free wheelAttach free wheel 2525 CCGG Mount lower postMount lower post 1515 CCHH Attach controlsAttach controls 2020 D, ED, E
II Mount nameplateMount nameplate 1818 F, GF, G
TotalTotal 244244
WorkWork TimeTime ImmediateImmediate
ElementElement DescriptionDescription (sec)(sec) Predecessor(s)Predecessor(s)
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
Example 7.3Example 7.3
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Line Balancing Big BroadcasterBig Broadcaster
Figure 7.12Figure 7.12
4040
66
2020
5050
1515
1818
E3030
2525
4040H
I
D
B
F
C
A
G
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Desired output rate, rmust be matched to the
staffing or production plan.
Cycle time, cis the maximum time allowed for work on a unit at
each station:1
rc=
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Desired output rate, r = 2400 unit/week
Plant operates 40 hours/week
r=2400/40 = 60 units/hour
Cycle time, c =1/60
=1 minute/unit
= 60 seconds/unit
1
r
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Theoretical minimum (TM ) - sum of all work-element
standard times divided by the cycle time.
TM =244 seconds/60 seconds =4.067
It must be rounded up to 5stations
Cycle time: c=1/60=1 minute/unit = 60 seconds/unit
Efficiency (%) - ratio of productive time to total time.
Efficiency= [244/5(60)]100= 81.3%
Balance Delay - amount by which efficiency falls short of 100%.
(100 81.3) =18.7%
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Line Balancing Big BroadcasterBig Broadcaster
c = 60 seconds/unitc = 60 seconds/unitTM = 5 stationsTM = 5 stations
Efficiency = 81.3%Efficiency = 81.3%
S1
S2
S3
S5S4
Figure 7.13Figure 7.13
40
6
20
50
15
18
E30
25
40H
I
D
B
F
C
A
G
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30
E,F,G F 55 5
Cumm Idle
Station Candidate Choice Time Time
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From-To Chart
Processes:
X, Y, Z, Q, and R
Parts that are manufactured through theseprocesses:
Part Nos.: 1, 2, & 3
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From-To ChartTo
From
X
Y
Z
Q
R
X Y Z Q R Total
Total
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From-To ChartTo
From
X
Y
Z
Q
R
X Y Z Q R Total
Total
Process Sequence: Part No. 1= X to Y to Z to R to Q
1
1
1
1
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From-To ChartTo
From
X
Y
Z
Q
R
X Y Z Q R Total
Total
1
1
1
1
Process Sequence: Part No. 3= X to Y to Z to Q to R
2
2
2
3
3
3
3
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From-To ChartTo
From
X
Y
Z
Q
R
X Y Z Q R Total
Total
1
1
1
1
2
2
2
3
3
3
3
3
2
2
2
3
3 33
1
1111
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Soal 1
Tata letak sebuah rumah sakit ditunjukkan sebagai berikut
Proses
Awal
(1)
RuangRecovery
(7)
Cast-SettingRoom
(8)
X-Ray
(4)
RuangOperasi
(6)
Exam
Room 2
(3)
Lab EKG
(5)
Exam
Room-1
(2)
40
10
10
Adapun pergerakan jumlah pasien antar diperlihatkan
sebagai berikut :
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(1) (2) (3) (4) (5) (6) (7) (8)
(1) 100 100
(2) 50 20
(3) 30 30
(4) 20 20
(5) 20 10(6) 30
(7)
(8)
Tentukan tata letak yang optimal berdasarkan
orientasi proses
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(1) (2) (3) (4) (5)
(1)
(5)
(4)
(3)(2)
(5)(1)
(2) (4)(3)
4 4 4 4
4 4
4
3
14
12
10 8
8 13
11 11
4 4
5 58 8
(1) Refrigerator
(2) Counter
(3) Sink
(4) Storage
(5) Stove
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Soal 4
Sebuah industri memiliki target produksi sebanyak 500
unit perminggu dengan waktu efektif kerja sejumlah 4000
menit per minggu. Pengerjaan produk tersebut dilakukanmelalui proses (tugas) sebagai berikut
Tugas waktu (menit) tugas sebelumnya
A 5 -
B 3 A
C 4 B
D 3 B
E 6 C
F 1 C
G 4 D,E,F
H 2 G
Tentukan waktu siklus, jumlah stasiun kerja, dan efisiensi.
Gambarkan diagram precedence kegiatan tsb
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Soal 5
Sebuah industri perakitan perahu menyediakan waktu
sebanyak 200 menit per harinya untuk kegiatan perakitan
perahu. Permintaan setiap harinya adalah 60 unit perahu.Adapun kegiatan perakitan dapat diuraikan dengan tugas-
tugas sebagai berikut :
Tugas waktu (menit) tugas sebelumnya
A 1 -
B 1 A
C 2 A
D 1 C
E 3 C
F 1 C
G 1 D,E,F
H 2 B
I 1 G,H
Tentukan kondisi keseimbangan lini yang diinginkan
sehingga kegiatan dapat optimal
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Soal 6
Sebuah perusahaan minuman memiliki waktu kerja 5 jam per hari dan
5 hari seminggu, mempunyai target permintaan sebesar 3000 botol
per minggu Pengerjaan produk tersebut dilakukan melalui proses(tugas) sebagai berikut
Tugas waktu (menit) tugas sebelumnya
1 0,1 -
2 0,1 13 0,1 2
4 0,2 2
5 0,1 2
6 0,2 3,4,5
7 0,1 1
8 0,1 79 0,2 7,8
10 0,1 9
11 0,2 6
12 0,2 10,11
13 0,1 12