REDESIGN OF THE SUSTAINABILITY LAYOUT OF PRODUCTION FLOOR FACILITIES (CASE STUDY: PT. KUNANGO JANTAN)

Putra, Hafizh Raufal (2025) REDESIGN OF THE SUSTAINABILITY LAYOUT OF PRODUCTION FLOOR FACILITIES (CASE STUDY: PT. KUNANGO JANTAN). S1 thesis, Universitas Andalas.

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Abstract

The manufacturing industry in Indonesia, particularly in the steel pole production sector, has experienced rapid growth. However, this growth brings challenges related to operational efficiency and environmental impact. PT. Kunango Jantan, which manufactures steel poles for the electrical sector, faces issues with the efficiency of its material handling flow on the production floor. The production process, which involves three main stages—pressing, assembly, and coating—requires careful management of material flow. Inefficient material transfer distances result in high costs, with material handling expenses reaching Rp1,532,041.67 per cycle. Additionally, the use of forklifts for material transfer contributes to increased CO₂ emissions due to energy consumption. This study aims to redesign the production facility layout at PT. Kunango Jantan to improve efficiency by reducing material transfer distances, lowering operational costs, and minimizing environmental impact. The research applies the Systematic Layout Planning (SLP) method to analyze the material flow, followed by CRAFT (Computerized Relative Allocation of Facilities Technique) to optimize the proposed layout. The design also integrates sustainability principles, focusing on reducing energy consumption and emissions, while supporting environmental sustainability. Furthermore, the environmental impact is calculated using SIMAPRO software to evaluate the emissions resulting from energy usage in material handling. The research results show that the redesign of the production layout from a process layout to a product layout successfully reduced material handling costs by IDR 238,334.70 and decreased CO₂ emissions by 17.25% (equivalent to a reduction of 1.22 kg CO₂eq). The proposed layout change improved operational efficiency while supporting environmental sustainability by reducing forklift fuel consumption. Before the layout improvement, forklift fuel consumption reached 15.35 liters of industrial diesel per cycle, whereas after the improvement, it decreased to 12.70 liters. Based on greenhouse gas (GHG) emission analysis, diesel forklifts produced 5.86 kgCO₂eq, while electric forklifts produced 23.78 kgCO₂eq. Although the GHG emissions of electric forklifts are higher, the energy consumed from non-renewable resources is only 248 MJ, while diesel forklifts consume 556 MJ, indicating a significant reduction in abiotic depletion. Abiotic depletion refers to the depletion of non-renewable natural resources such as fossil fuels and minerals. The final evaluation of the layout design showed an 11.43% improvement score, reflecting a significant enhancement in material flow efficiency and space utilization, mainly due to the reduction in previously non-optimal material transfer distances.

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