Proceedings of the International Conference on Industrial Engineering and Operations Management

Istanbul, Turkey, March 7-10, 2022

Production Layout Replanning Using Systematical Layout

Planning with Shared Storage Method Analysis and Flexsim
Simulation in Garment and Textile Company
James Laurent, Lina Gozali, Ricky Farrel, Carla O. Doaly
Department of Industrial Engineering
Faculty of Engineering
Universitas Tarumanagara
Jl. S. Parman No 1, Jakarta, 11440, Indonesia
james.545180046@stu.untar.ac.id, linag@ft.untar.ac.id, ricky.545210004@stu.untar.ac.id,
carlaol@stu.untar.ac.id

Abstract
PT. XYZ is a small to medium business engaged in producing children's apparel that produces various product
designs, such as jumpsuits, dresses, and clothes for children from 0-1 years old. PT. XYZ still has problems in the
production sector, such as the missed production process, the production layout, which is considered ineffective
compared to production standards. The Warehousing system is dangerous and takes massive time and energy. So the
researchers conducted direct observations and implementations in the field using data obtained from operations such
as the amount of production, flow, time, and the number of employees. The new layout is processed by using a
systematic layout planning method. SLP method calculation consists of From To Chart (FTC), Operation Process
Chart (OPC), Routing Sheet, Multi-Product Process Chart (MPPC), Activity Relationship Chart (ARC), Activity
Relationship Diagram (ARD), Area Allocation Diagram(AAD), and flow processes to design new layouts and use
shared storage methods Throughput, Assignment, Calculation of needs and space. After being processed, the results
of the 2 alternative designs have effectiveness, distance, and shorter time than the initial layout. From the two
alternatives, simulations were carried out using the Flexsim application and compared the time and production
throughput. Alternative number one was chosen because the production throughput was 2 more pieces than
alternative 2, with an increase of about 11.4% compared to the initial layout. The final step is implementing the final
design that has been selected at the production site.
Keywords
Facility Layout, Systematic Layout Planning, Shared Storage, Implementation

1. Introduction
The layout is one of the keys that determine the efficiency of a company's operations in the long term. An
effective layout can help an organization achieve a strategy that supports differentiation, low prices, or
responsiveness. The layout emphasizes systematic and logical design using multiple analytical processes.

PT. XYZ is a business engaged in textile production, with 2 production sites and 1 sales shop. The product
produced by PT. XYZ is clothing for girls aged less than 2 years. Based on observations of the production layout,
the main problem is the frequency of technical errors in production such as wrong colours or missed processes due
to layouts that confuse workers in processing materials and the distance between the previous machine and the
sewing machine is quite far. Also, the road area is very narrow due to the machine's large size. The layout is also
considered poor due to excessive activity in the material transportation process. Much time is wasted, making it
more costly and less effective. And the distance between the raw material warehouse and the production process is
quite far, where the raw materials are large and quite heavy, with many material handling processes making the
process quite time-consuming and laborious, as well as dangerous.

Therefore, research was conducted by redefining the layout and emphasizing the shared storage method for
warehouses. The research uses a systematical layout planning method in determining the layout and design, with
input analysis based on warehousing management so that storage placement is more effective.

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

1.1 Objective
1. Provide a layout plan designed using a systematic method on PT. XYZ.
2. Analyze and redesign the system layout of the warehouse placement using the Shared Storage method.
3. Improve the workplace that has been systematically arranged and tested

2. Literature Review
The literature reviews that are used in this research are:

2.1 Systematic Layout Planning

Systematic Layout Planning is a series of stages in planning a layout, starting from the pattern outline and
placement to the final layout. These stages use several tools such as Routing Sheet, ARC, AAD, MPPC, and ARC
1. Operation Process Chart
Operation process chart (OPC) is a diagram that describes the process steps experienced by raw materials
regarding the sequence of operations and inspections from the beginning to the finished product as a whole
or as a component. It contains the information needed for further analysis. So in an operation process chart,
only operations and inspection activities are recorded, sometimes at the end of the process storage is
recorded (Sutalaksana & Iftikar, 2006). carry on.
2. Routing Sheet
Sequencing of production becomes the backbone of production activities which is the recollection of all
data developed by process engineers and the main communication tool between product engineers and
production people. A production routing sheet is a tabulation of the steps involved in producing a particular
component and the necessary details of related matters. This routing sheet is often referred to as a process
or operation sheet (Apple, 1977). The aim is to calculate the number of machines, production quantities and
time in detail to determine the theoretical capacity of the tool for the next stage.
3. MPPC
MPPC (Multi-Product Process Chart) is a diagram that shows the order for each component to be produced.
The MPPC map can be useful as a general description of the processing steps. The sequence of production
from each component to produce in each machine. Based on the MPPC, it can also be seen that
backtracking and flow patterns are not in accordance with the process sequence (Ariana, et al, 2005).
4. From To Chart
From to Chart is one of the conventional techniques used in general in designing facility layouts and
transferring materials in a production process. From to Chart (FTC) is calculated with the total of material
handling costs for each displacement that occurs (Wignjosoebroto & Sritomo, 2003). The final result of the
FTC is a number that will be converted into a relationship value that will be used to design the Activity
Relationship Chart.
5. Activity Relationship Chart
Activity Relationship Chart (ARC) is a simple method or technique in planning the layout of a facility or
department or based on the degree of activity relationship, often expressed in a "qualitative" assessment and
tended to be based on subjective considerations of each individual in each facility/department. ARC will
consider the degree of proximity of a department to other departments with qualitative measures such as:
absolute or not absolute, must be close together, important enough to be placed close together and so on.
6. Activity Relationship Diagram
Activity Relationship Diagram is a diagram that describes the various activity flows in the system that is
being designed, how each data flow begins, the decisions that may occur and how they end. Activity
diagrams are special state diagrams, where most of the states are actions and most of the transitions are
triggered by the completion of the previous state of internal processing. Therefore, the activity diagram
does not describe the internal behaviour of a system exactly but rather describes the processes and activity
paths from the top level in general.
7. Area Allocation Diagram
Area Allocation Diagram (AAD) is principally an area template compiled based on ARD. AAD describes
the final layout, but each activity centre does not contain facilities yet. Area Allocation Diagram (AAD) is a
continuation of ARC where the proximity of the activity layout is determined in Area Allocation Diagram
(AAD). AAD is also a global template of information that can be seen only in area utilization. In contrast,
the complete image can be seen in the template, which is the final result of the analysis.

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

2.2 Shared Storage

Shared storage is a method of arranging the layout of the warehouse space using the FIFO (First In First
Out) principle, where the goods that are sent the fastest are placed in the storage area closest to the exit entry (I/O)
door. This method would be better used in types of factories that have the same product dimensions or are not much
different because each storage area can be occupied by different types of products based on the product's production
time and delivery date (Zaenuri, 2015). The steps taken in solving the problem are as follows (Mulyati, et al, 2020) :
1. Data Collection Average Amount of Goods Out of Warehouse
The first stage in Shared Storage collects data on the entry of raw material goods into the warehouse,
from all types of materials calculated separately.
2. Data Collection Average Amount of Goods Entered the Warehouse
The next stage is data collection of goods brought to the production floor, also calculated separately for
each material supplied. Furthermore, from the data on the average number of exits from the warehouse
and entry into the warehouse, the number of monthly usages with a period of time for each material is
calculated, and the number of monthly needs for each raw material is obtained.
3. Space Requirements
Next is the space required by calculating the number of raw materials divided by the storage capacity of
one pallet of each raw material.
4. Determination of Aisle Width
Determination of Aisle Width aims to calculate the best pallet size and the width of the aisle or aisle
between each pallet available to store raw materials. The aisle is actually the diagonal of the pallet size.
5. Throughput Perhitungan
Throughput is a point that shows how often a raw material is moved or material handling. It is
calculated from the number of needs per month divided by the number of storage of 1 production pallet.
6. Assignment Calculation
Basically, Assignment is Throughput multiplied by the number of room requirements, usually directly
proportional to Throughput.
7. Distance from Warehouse Area to Door
From the previously calculated points, the next step is to design a layout based on the distance from the
door to the material pallet, where each material pallet is ordered based on the calculated assignment
point. The bigger it is, the closer it should be to the door.
8. Final Layout
Only at this stage was the final layout designed with different numbers and colour designs for each
material.

2.3 Flexsim
Flexsim is a production simulation application that aims to understand the design and simulate a factory or
facility in carrying out the production process. Flexsim aims to minimize a design by simulating it first, from which
it can be improved and revised before direct implementation. Using the application starts from placing the
production components, such as processor, combiner, separator, queue or docking area, then each component is set
production time and setup time. The next step is to connect each component with a connecting line, and each line
and component is paired with transporters and workers who can be workers, locomotion equipment, to robots. After
everything is designed, the last step is to do a simulation directly and see the selected parameters. If the results are
good, then the simulation is declared feasible to be implemented directly.

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

3. Method
The method that has been done in this research can be seen in the flowchart in Figure 1.

Figure 1. Method Chart

4. Data Collection
Here is the Previous Factory Layout in Figure 2, and with the average of production demand and production
planning per month.

Figure 2. Initial Layout Facility

Figure 3. Assumption Production Figure 4. Area total

5. Results and Discussion

5.1 Systematical Layout Planning
Systematical layout planning starts with several calculations using OPC, FTC, MPPC, Routing Sheet, ARD,
AAD, and final layout.
1. Operation Process Chart

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

The Operation Process Chart of this Research can be seen in Figure 5

Figure 5. Operation Process Chart

2. Routing Sheet
The Routing Sheet of this Research can be seen in Figure 6

Figure 6. Routing Sheet

3. MPPC

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

The MPPC of this Research can be seen in Figure 7

Figure 7. Multi Product Process Chart

4. From To Chart
The From To Chart (FTC) of this Research can be seen in Figure 8 and Figure 9, as well as the relations
table in Figure 10

Figure 8. FTC Inflow

Figure 10. Relations From To Chart

Figure 9. FTC Outflow

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

5. Activity Relationshion Chart

The Activity Relationship Chart of this Research can be seen in Figure 11

Figure 11. ARC

6. Activity Relationship Diagram

The Activity Relationship Diagram of this Research can be seen in Figure 12 and 13.

Figure 12. ARD Alternative 1 Figure 13 ARD Alternative 2

7. Area Allocation Diagram

The Area Allocation Diagram of this Research can be seen in Figure 14 and 15.

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

Figure 14. AAD Alternative 1 Figure 15. AAD Alternative 2

8. Layout
The Layout Detail of this Research can be seen in Figure 16.

Figure 16. Layout Details

5.2 Shared Storage

Shared Storage starts from calculating production needs, space requirements, aisle width, Throughput,
assignment, and area distance in determining the final warehousing layout.
1. Production Needs
The Production needs of this research can be seen in Table 1.

Table 1. Production Needs

Production Needs
N
Material type Goods Amount (Roll) Period (Months) requirements
o
1 White Cotton Cloth 240 15 16
2 Light Color Cotton 852 6 142
3 Dark Color Cotton 372 48 7,75
4 Printed Cotton Fabric 400 1 400
5 Furing Cloth 24 6 4
Production Needs
N
Material Type Goods Amount (Roll) Period (Months) requirements
o
6 Jumpsuit 1656 2 828
7 Shirt 265 2 132,5
8 Dress 624 3 208

2. Space Requirement
The Space Requirement of this Research can be seen in Table 2

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 Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

Table 2. Space Requirement

Space Requirement
No Material type Goods Amount (Roll) Pallet Capacity Space Requirement Rounding
1 White Cotton Cloth 240 144 1,666666667 2
2 Light Color Cotton 852 144 5,916666667 6
3 Dark Color Cotton 372 144 2,583333333 3
4 Printed Cotton Fabric 400 144 2,777777778 3
5 Furing Cloth 24 144 0,166666667 1
Space Requirement
No Material Type Goods Amount (Roll) Pallet Capacity Space Requirement Rounding
6 Jumpsuit 1656 Lusin 600 2,76 3
7 Shirt 265 600 0,441666667 1
8 Dress 624 600 1,04 1

3. Aisle
The Aisle of this Research can be seen in Table 3.

Table 3. Aisle

Wide Height Volume Area Diagonal/

Size Lenght (M) (M) (M) (M3) (M2) Aisle
1 Pallet Size 1,5 1 2 3 1 1,802775638
1 Rack Size 2 1 3,5 7 2 2,236067977

4. Throughput
The Throughput of this Research can be seen in Table 4.

Table 4. Throughput

Throughput
N Goods Amount Period requirement Throughput
Material type Throughput
o (Roll) (Months) s Rounding
White Cotton 0,11111111
1 240 15 16
Cloth 1 0,1
Light Color 0,98611111
2 852 6 142
Cotton 1 1
0,05381944
3 Dark Color Cotton 372 48 7,75
4 0,05
Printed Cotton 2,77777777
4 400 1 400
Fabric 8 2,77
0,02777777
5 Furing Cloth 24 6 4
8 0,02
Throughput
N Goods Amount Period requirement Throughput
Material Type Throughput
o (Dozen) (Months) s Rounding
6 Jumpsuit 1656 2 828 1,38 1,38
0,22083333
7 Shirt 265 2 132,5
3 0,22
0,34666666
8 Dress 624 3 208
7 0,35

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 Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

5. Assignment
The Assignment of this Research can be seen in Table 5

Table 5. Assignment
Assignment
Space
No Material Type Throughput Space Requirement Assignment
Throughput Rounding Requirement Rounding Assignment Rounding
White Cotton
1
Cloth 0,111111111 0,1 1,666666667 2 0,055555556 0,06
Light Color
2
Cotton 0,986111111 1 5,916666667 6 0,164351852 0,16
Dark Color
3
Cotton 0,053819444 0,05 2,583333333 3 0,017939815 0,01
Printed Cotton
4
Fabric 2,777777778 2,77 2,777777778 3 0,925925926 1
5 Furing Cloth 0,027777778 0,02 0,166666667 1 0,027777778 0,02
Assignment
Space
No Material Type Throughput Space Requirement Assignment
Throughput Rounding Requirement Rounding Assignment Rounding
6 Jumpsuit 1,38 1,38 2,76 3 0,46 0,5
7 Shirt 0,220833333 0,22 0,441666667 1 0,220833333 0,2
8 Dress 0,346666667 0,35 1,04 1 0,346666667 0,3

5.3 Validation
1. Alternative 1
The following is the 3D design of alternative layout one that has been pre-designed, with sufficient
Throughput or production quantities produced, and the division of the working process of each machine
that works. After the design is done in the Flexsim application, test the layout model with parameters,
namely the amount of Throughput or the number of production and the state bar that shows the state of
the machine time from start to finish. Run time on the simulation is 10 hours of work. Following is the
result of the simulation of alternative layout model 1.

Figure 17. Floor 2 Alternative 1

Figure 19. Simulation 1

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

Figure 18 Floor 3 Alternative 1

2. Alternative 1
The following is the 3D design of alternative layout 2 that has been pre-designed, with sufficient
Throughput or production quantities produced, and the division of the working process of each machine
that works. After the design is done in the Flexsim application, test the layout model with parameters,
namely the amount of Throughput or the number of production and the state bar that shows the state of
the machine time from start to finish. Run time on the simulation is 10 hours of work. Following is the
result of the simulation of alternative layout model 1.

Figure 20. Floor 2 Alternative 2

Figure 22. Simulation 2

Figure 21. Floor 3 Alternative 3

3. Comparison
From the simulation results that have been carried out, alternative 1 is chosen due to the amount of
Throughput that exceeds alternative 2 by 2 piece dress. The main changes are obtained from the flow of the
production and the number of machines. The new layout design, resulting in an increase of 11.36% higher than the
layout before rearranging (322 Pieces). Another comparison is that the state bar of alternative 1 has the number of
products in the MP Bis machine, Sewing Machine, Overlock, Khamp, Rub, QC, and Packing are slightly higher than
alternative 2. However, alternative 2 reaches the cutting machine with a higher processing result. In this study, the
researcher used the amount of production as the important factor to choose the best alternative as a new design used
for the final implementation. Here are the results selection and final layout of the layout design.

5.4 Proposed Improvements

Proposed Improvements of Final layout after Calculations using Systematical Layout Planning and Shared
Storage, and the Simulations using Flexsim can be seen in Figures

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Proceedings of the International Conference on Industrial Engineering and Operations Management
Istanbul, Turkey, March 7-10, 2022

Figure 23. Final Layout

6. Conclusion
This research provides several alternative layout results with the calculation of shared storage and systematic
layout planning. The result calculation obtained two alternative design layouts. The chosen design layout is obtained
from the number of productions and better simulation results, The output obtained from layout 1 is 367 pieces,
more than the result of design layout 2, which is 365 pieces. The average number of products in cutting, Kamp, and
ironing machines shows higher results than the average production of alternative 2 which only shows high
production in cutting and embroidery machines. The average production time in design layout 1 increased by 6.16%
improvement. The simulation results show that Alternative 1 is 11.39% more productive than the initial layout. The
results of the warehouse layout using the Shared Storage method. The structure of a warehouse rack using
calculations such as Assignment, Throughput, and others For fabrics that have the largest Assignment value, Cotton
Printing is 0.92 and the smallest assignment value is Dark Cotton Fabric with 0.01 points. The value of printing
cotton fabrics with a high assignment value is placed close to the door to make it easier to handle the material. And
for finished materials, the highest Assignment is Jumpsuit with 0.46 points, and the lowest is T-shirt with 0.22, so
the Jumpsuit is placed close to the door.

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Biography
James Laurent is a Industrial Engineering Student from Tarumanagara University. Born in Jakarta, 15 September
2000 as the first of three siblings. Graduated from Ricci 1 Elementary, Middle, and High School with a major in
Science, participated in OSN (National Science Olympics) in Astronomy and achieved the 5th position of all Jakarta
students. Entered Tarumanagara University in 2018 and dream to be a Bussinesman in the future.

Lina Gozali is a lecturer at the Industrial Engineering Department of Universitas Tarumangara since 2006 and a
freelance lecturer at Universitas Trisakti since 1995. She graduated with her Bachelor's degree at Trisakti
University, Jakarta - Indonesia. She got her Master's Degree at STIE IBII, Jakarta – Indonesia, and she recently got
her PhD at Universiti Teknologi Malaysia, Kuala Lumpur – Malaysia, in 2018. Her apprentice college experience
was in the paper industry at Kertas Bekasi Teguh, shoe industry at PT Jaya Harapan Barutama and automotive chain
drive industry at Federal Superior Chain Manufacturing. She teaches Production System and Supply Chain
Management Subjects. She researched the Indonesian Business Incubator for her PhD. She has written almost 70
publications since 2008 in the Industrial Engineering research sector, such as Production Scheduling, Plant Layout,
Maintenance, Line Balancing, Supply Chain Management, Production Planning, and Inventory Control. She had
worked at PT. Astra Otoparts Tbk before she became a lecturer.

Carla Olyvia Doaly is a lecturer in the Industrial Engineering Department at Universitas Tarumanagara graduated
with my bachelor's degree from Institut Teknologi Nasional Malang, which study the Industrial Engineering
program, then continued my Master Degree at Institut Teknologi Bandung majoring in Industrial engineering and
management and a special field of Enterprise Engineering. She is very interested in studying industrial engineering
by doing research related to System Design and Engineering, Supply Chain Management, Operations Research and
Analysis, Information System Management, Occupational Health and Safety, Facilities Engineering, Quality and
Reliability Engineering

Ricky Farrel is a Industrial Engineering Student from Tarumanagara University. Born in Tangerang, 20 th of April
2003 as the second of two siblings. Graduated from Poris Indah Elementary, Middle, and High School with major in
Science, and participated in singing competitions and managed to be finalist. Entered Tarumanagara University in
2021 and dreams to be an Entrepreneur in the future.

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