TI4101 Perancangan Tata Letak Pabrik

Pekenalan Software VIP-PLANOPT

Program Studi Teknik Industri Institut Teknologi Bandung 2010

Outline
VIP-PLANOPT
Introduction Terminology How to Use? Performance Comparison to Other Software

Conclusion

Program Studi Teknik Industri ITB

TI4101 Perancangan Tata Letak Pabrik

INTRODUCTION

Introduction (1)

What?
Motivation (Productivity and profitability)
Program Studi Teknik Industri ITB

VIP-PLANOPT (Visually Interfaced

Package of floor-PLAN layout OPTimization)

20-50% of operating cost relates to material handling US business spend about trillion dollar on new facilities

TI4101 Perancangan Tata Letak Pabrik

Introduction (2)
Filling the Gap
Guaranteed superiority on other algorithm for low-cost layout Has a record of UNBEATEN PERFORMANCE with a money back guarantee

Unmatched Functonality
Program Studi Teknik Industri ITB

User-specified pick-up and drop-off points Allow any number facilities to be anchored Specify the shape and the size Module Padding Forbidden Area Module No-Flow Modules

TI4101 Perancangan Tata Letak Pabrik

Introduction (3)
Better than all GAs, SAs and the conventional analytical or heuristic techniques Has not been published Introduced double precision arithmetic Introduce new techniques to reduce dependence the user-specified Introduction Penalty functions using boundary shape

Optimization Algorithm

Program Studi Teknik Industri ITB

TI4101 Perancangan Tata Letak Pabrik

TERMINOLOGY

Terminology (1)
Representing departments, machines, rooms, cells, or spaces

MODULE
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TI4101 Perancangan Tata Letak Pabrik

Terminology (2)
Ri = Wi/Li Ai = Wi * L i Hard vs Soft (x, y) Movable vs Anchored
Program Studi Teknik Industri ITB

Module Aspect Ratio

Module Area Module Type Module Placement Module Position
TI4101 Perancangan Tata Letak Pabrik

Terminology (3)
Not Fuctional Facility

Forbidden Area Module (FAM)

Fixed vs May Flipped

Empty Space

Module Orientation
Module Padding Pick-up & Drop-off Points Boundary Shape
TI4101 Perancangan Tata Letak Pabrik

(ex : Allowance)
Centroid or No Restriction of Facility
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Terminology (4)
Bounding rectangle enclosing the modules in a layout

ENCLOSURE
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Terminology (5)
Number of material flow Cost of transporting a unit load per unit distance

Flow Matrix Unit Cost Matrix

Cost Matrix
TI4101 Perancangan Tata Letak Pabrik

Total Cost each material flow

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How To Use ?
(In PTLP 2011)

How To Use? (1)

Define The Modules Input Flow Matrix

Input Cost Matrix per Unit

Making Boundary Shape

Placement Anchored Modules

Optimize the Problem

Search Optimal Solution

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How To Use? (2)

Define The Modules
1
1 3 2 4 Define Dimension

Define Module Type

Define Module Orientation Define Module Position

3
4

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How To Use? (3)

Input Flow Matrix & Cost Matrix Per Unit
6 7 5

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How To Use? (4)

Making Boundary Shape

9 10 8

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How To Use? (5)

Placement Anchored Modules
12

11

13

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How To Use? (6)

Optimize the Problem
15

14

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How To Use? (6)

Search Optimal Solution
17

16

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PERFORMANCE

Performance (1)
Calculation Time
No
1 2` 3 3 8 20

Number of Modules

Conditions
Symetric cost matrix

Calculation Time/Solution
0.004 seconds

8 Hard modules of unequal areas 0.008 seconds Symetric cost matrix 20 unequal areas Optimal solution 1157! Best published solution 1264 0.059 seconds

4 5 6

50 100 125

2.383 seconds 11.91 seconds 29.664 seconds

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Performance (2)
Example of Layout Solution (20 Modules)

Iteration #3

Iteration #40

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Performance (2)
Example of Layout Solution (125 Modules)

Program Studi Teknik Industri ITB

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COMPARISON TO OTHER SOFTWARE

Comparison to Other Software

VIP-PLANOPT vs Craft (PTLP Case)
CRITERIA Input VIP-PLANOPT (PTLP 2011) Facilities Dimension, Unit Cost Matrix, Flow Matrix, 41 (0-40) composite Square, 1 facilities = 1 square Location, machine 100-200 million rupiahs CRAFT (PTLP 2010) Unit Cost Matrix, Flow Matrix, Initial Layout Coordinate, Not specified square Square, Letter L 1 facilities > 6 squares Location 90-140 million rupuiahs

Number of iteration Boundary Shape Facilities Shape Facilities Form Solution Range

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Conclusion

Conclusion
Conclusion
VIP-PLANOPT has been proved that could give better solution in many problems compared with any other approach. But, VIP-PLANOPT give worse solution in PTLP case. That is because the lack of experience in using this powerful software. Also user must define the PTLP case more detail when using the software. It is because VIP-PLANOPT provides more parameter which is very relevant with the real system.

1 2 3

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THANK YOU!!!
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Production Planning and Control System