TOFU PRODUCTION FACILITY LAYOUT REDESIGN USING SLP TO REDUCE MATERIAL HANDLING DISTANCE AND COST

Abstract

This study aims to redesign the production facility layout of Usaha Tahu Pak Suryono to reduce material handling distance and material handling cost. The observed problem was an irregular initial layout that caused detours, long movement routes, and inefficient relationships among production areas. The research used Systematic Layout Planning (SLP) supported by BLOCPLAN90. Primary data were collected through field observation, interviews, and documentation of production flow, work area dimensions, material movement distance, movement frequency, and labor-based material handling cost. The SLP stages included process identification, activity relationship analysis, worksheet preparation, activity relationship diagram development, space requirement analysis, alternative layout generation, and comparison of the initial and proposed layouts. The selected third layout alternative obtained an adjacency score of 1.00 and a relative distance score of 0.94. The proposed layout reduced daily material handling distance from 516 m to 348 m and decreased material handling cost from IDR 74,562 to IDR 50,286, representing an efficiency improvement of 32.56%. Therefore, the proposed layout can improve material flow and production efficiency.