Facility Layout Redesign to Improve Material Handling Efficiency in Colored Stone Production at PT Tatalogam Lestari

Abstract

Facility layout efficiency and material handling are important for improving manufacturing performance. An inappropriate layout can increase material travel distance, movement frequency, and Material Handling Cost (MHC). This study aims to redesign the facility layout for the colored stone production process at PT Tatalogam Lestari and evaluate its impact o?n material travel distance and MHC. A quantitative approach was applied using field observations, interviews, facility measurements, and material movement data. The redesign employed the Activity Relationship Chart (ARC), Total Closeness Rating (TCR), and Blocplan methods, while material travel distance was calculated using the rectilinear distance approach. The results show that the proposed layout reduced material travel distance from 30,019.18 to 27,057.64 meters/day, a reduction of 2,961.54 meters/day or 9.87%. MHC decreased from IDR 1,395,846.49 to IDR 1,155,276.42/day, generating savings of IDR 240,570.07/day or 17.23%. The proposed layout improves material handling efficiency and operational cost performance.