DETERMINATION OF PRODUCTION PROCESS AND NUMBER OF

MACHINE USED

PRACTICUM SUBSTANCE
Analysis production targets and the machine required
PRACTICUM OBJECTIVE
1. Students are able to create and analyze products using Bill of Material to
identify the needs of the process
2. Students are able to create Operation Process Chart and Precendence Diagram
for sorting the process requirement
3. Students are able to understand and calculate the routing sheet to determine
the amount of machine required in the process.
4. Students are able to determine and analyze the machine required to meet the
target of production by using routing sheet
PRACTICUM TOOLS
1. Microsoft Excel
2. Microsoft Visio

PRACTICUM REQUIREMENT
1. Guideline

Study Case
PT PFT produce trolley with total production demand is 5940 per year (Reference:
data demand from praktikum tekmi PFT Inc. will determine the facilities used using
data input demand (TEKMI. The working days for the labor are 5 days (with working
hour is 8 hour per day) and shift working per-day is 1 . PFT Inc. has 13 facilities
based on operation process mapping and 5 facilities. In warehouse maximum stack
for all material 1,8 m because taking all goods using human reach.
Table facilities measuring 120 x 60 x 75 cm, molding machine size 7 x 5 x 3 m, press
machine 7 x 8 x 5 m.
Steps of practicum
Routing sheet
1) Fill in the operation number, facility name, Processing time, machine
efficiency and defect in the routing sheet table based on the OPC that has
been made!

Processing Theoretical Actual

Operation Facility time machine Efficiency machine Defect
No
name (menit) capacity (%) capacity (%)
(unit/day) (unit/day)
A B C D E F G

2) Calculate the theoretical machine capacity and actual machine capacity using
the formula given!
Theoretical Actual machine
machine capacity efficiency capacity
(unit/day) (%) (unit/day)
D E F
Note : lot size is the number of products produced in a single process
 Theoritical machine capacity :

Lot Size x Working hour /day

Processing time

 Actual machine capacity :

Theoritical machine capacity x machine efficiency

3) To fill the required production amount and prepared production amount, the
calculation starts from the last process in the trolley production process that
is inspection (I-4) and follows the order of OPC steps (note the sequential
stages for each calculation). Step-by-step of the process are as follows :
a) Fill the last cell of the required production amount on the last inspection
(I-4) using the formula!
Demand per Day (A) :

Demand per year (reference)

working days/year

Required Prepared
production production
amount(unit/day) amount (unit/day)
I J
Sub Assembly 5 (Assembly 4 + Handle)
26 27
26 26
A=25 26

Next, calculate the amount of production that should be prepared for

inspection I-4 using the formula!
Prepared production amount (B) :

𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑎𝑚𝑜𝑢𝑛𝑡

1 − (𝑑𝑒𝑓𝑒𝑐𝑡 𝑥 𝑙𝑜𝑜𝑝𝑖𝑛𝑔 𝑝𝑟𝑜𝑐𝑒𝑠𝑠)
 Defect Required Prepared
Jumlah
Facility (%) production production
No Operation Mesin
Name amount(unit/day) amount
Aktual
(unit/day)
A B G H I J
Sub Assembly 5 (Assembly 4 + Handle)
Meja
O-9 Assembly 1% 0 26 27
12 5
Area 26
I-4 0% 0 26
Inspeksi
Meja
O-10 1% 0 25 B=26
Packaging

b) Next, the required production amount for O-9 is determined from the
prepared production amount in the previous operation as shown in the
example below :
Required Prepared
production production
No Operation Facility name
amount amount
(unit/day) (unit/day)
A B I J
11 O-8 Meja Assembly 4 27 28
Sub Assembly 5 (Assembly 4 + Handle)
12 O-9 Meja Assembly 5 26 27
I-4 Area Inspeksi 26 26
Finishing
13
O-10 Meja Packaging 25 26

Repeat the step a and b for the next operation!(* Gradual process from
bottom to top based on OPC)
c) Calculate the theoretical machine required!
Theoretical machine required formula (C) :

𝑃𝑟𝑒𝑝𝑎𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑎𝑚𝑜𝑢𝑛𝑡

𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
 actual machine prepared production
capacity (unit/day) amount (unit/day) Machine required

Theoritical (unit)
F J K L
208 27 C=0.1345 1
Sub - Assembly 5 (Assembly 4 + Handle)
316,8 26 0.0852 1
640 26 0.0406 1
237.6 26 0.1094 1

Warehouse Floor Area

4) Input production/day which is 30 based on the prepared production amount
from upper routing sheet.
The formula to determine the Production / week = Production/day *
Working day/week.
5) Input the box dimension :
Box
Length (m) Width (m) Height (m)

0.75 0.5 0.15

a) The capacity in 1 box is 1 unit/box

b) Maximum Height of Stacking is 1.8 m (based on the long range) and the
number of box for 1 stacking is 12 from ( height of stacking/ height box)
c) The space for the stacking can be determined from :
length x width of box dimension
6) Input the requirements :
box required 150 unit
needs the number of stack 13 stack
floor space required 4.875 m2
 a) Box requirement :
Production per week / total capacity
b) The number of stacking :
Production per week / total capacity / number of box per stacking
c) Floor space requirement :
The number of stacking x the space for the stacking
7) Input Allowance :
Allowance (100%) 4.875 m2
Allowance
allowance of aisle (30%) 1.4625 m2

a) Allowance (100%) already covers three allowance (material, person and

moving material) :
Floor space requirement x 100%
b) Allowance (30%) :
Allowance (100%) x 30%
8) Warehouse area :
Floor space required + Allowance (100%) + Allowance of aisle
total of warehouse floor area 12 m2

9) Shipping floor area is 10% warehousing floor area

SHIPPING FLOOR AREA (10% warehouse
2 m2
floor area)
Total Requirements ( input the direct raw material warehouse)
10) Characteristics of Box Material :
CHARACTERISTICS OF BOX
Part name MATERIAL (m)
Length Width Height
Box 1.05 0.80 0.31
M6 + Nut (1) 0.10 0.10 0.05
Handle 0.68 0.32 0.38
Bracket 0.35 0.32 0.35
M6 + Nut (2) 0.10 0.10 0.05
Square Tube Profile 0.60 0.35 0.31
M5 40mm +Nut 0.10 0.10 0.05
Wheels 0.34 0.31 0.34
Square Tube 0.60 0.35 0.31
M4 0.10 0.10 0.05
Spring Cover 0.60 0.35 0.31
Spring Tube 0.60 0.35 0.31
Body 0.39 0.37 0.44
M5 25mm + Nut 0.10 0.10 0.05
Gear 0.39 0.37 0.44
Chasis 0.94 0.68 0.32
M6 +Nut (3) 0.10 0.10 0.05

11) Requirement of Total Material Needs :

TOTAL PART PER 1 PRODUCTION THE NUMBER OF

Part No. Part name
UNIT PER DAY PART REQUIRED

B02 Box 1 30 30
C02 M6 + Nut (1) 4 30 120

a) Production per day required :

From prepared production amount (upper = 30)
b) Total Part/1 unit :

From Product Structure

 c) Number of part required :
Total part per 1 unit X Production per day
Direct Raw Material Warehouse (GBBU)
12) Fill input data for GBBU :
Working days for PFT company 5 day/week, working hour 8 hour/ day and
shift working 1 shift/ day. In warehouse maximum stack for all material 1,8
m because taking all goods using human reach.
13) Determination of the Direct Raw Material Warehouse (GBBU) floor area :

Material amount of the number of

material material per floor area
Required / stack
required / stack
Material Lead Time per
day
week

Chasis 30 150 5 30 19.18

Gear 60 300 4 75 10.54

a) Amount of material required / day :

The number of part required
b) Amount of material required / Lead Time per week :
(material required/day) X shift X working days
c) Amount of material / stacking :
Maximal stack / height of box material
d) The number of stack :
(material required / lead time per week) / (The amount of material per
stack)
e) Floor Area
The number of stack x length of box material x width material
f) MHE allowance :
Floor space requirement * 20%
 total area required 81.17 m2
MHE allowance
16.23

total area GBBU 98.00 m2

Indirect Material Warehouse (GBBP)

14) Fill input data for GBBP :
Working days for PFT company 5 day/week, working hour 8 hour/ day and
shift working 1 shift/ day. In warehouse maximum stack for all material 1,8
m because taking all goods using human reach.
15) Determination of the Indirect Raw Material Warehouse (GBBP) floor area :
amount of the number of floor area
Material material per stack
material stack
Required /
Material required /
Lead Time per
day
week

Box 30 150 5 30 25.20

M6 + Nut (1) 120 600 36 17 0.17

a) Amount of material required / day :

The number of part required
b) Amount of material required / Lead Time per week :
(material required/day) X shift X working days
c) Amount of material / stacking :
Maximal stack / height of box material
d) The number of stack :
(material required / lead time per week) / (The amount of material per
stack)
e) Floor Area
The number of stack x length of box material x width material
f) MHE allowance :
Floor space requirement * 20%
 total area required 64.31 m2
MHE allowance
12.9

total area GBBP 78.0 m2

16) Determine the receiving floor area
a) Receiving Area:
30% * (total area GBBU +GBBP)
b) MHE Allowance :
Receiving area * 30%
Receiving Area 52.8
MHE Allowance 15.84
Total Receiving Area 69

Facility

17) Identify the facility used and the facility dimension size!
the name facility used can be defined based on these criteria :
a) machines (for automatic machines or machines larger than 1m)
b) Table (for small machines, which need to be done by the operator)
c) area (for small machines so operators need to work but not allow desk or
need space)
size of facility
No Facility + Image length Width Height
(meters) (meters) (meter)

1 1.2 0.6 0,75

Nama : Meja Inspeksi 1

18) Next, fill in the efficiency column based on each facility used!
 19) Next, fill in the lot size column
Lot size refers to the number of items produced in a single production
process. In other words, lot size basically refers to the total number of
products for manufacture.

20) Fill size area GBBU, GBBP, Werehouse, Shipping and Receiving

15 12 m2

Nama : Area Warehouse

16 2 m2

Nama : Area Shipping

21) Last input operators for each facility with the provision of one facility is one
operator
table of machines table of operator

No. Facility amount No. facility amount

1 Meja Inspeksi 4 1 Meja Inspeksi 4

2 Mesin Molding 2 2 Mesin Molding 2
3 Mesin Press 2 3 Mesin Press 2
4 Meja Sub Assembly 5 4 Meja Sub Assembly 5
5 Meja Packaging 1 5 Meja Packaging 1
Total 14
REFERENCE

[1] Sutalaksana, Iftikar, dkk, (1979), Teknik Tata Cara Kerja, Departemen Teknik
Industri – ITB, Bandung.
[2] Apple, James M., Tataletak Pabrik dan Pemindahan Bahan, Penerbit ITB,
Bandung, 1990.
[3] Tompkins, James A., et al., Facilities Planning, John Wiley & Sons, Canada,
1996.