Optimalisasi Tata Letak Fasilitas dan Material Handling Berbasis Lean Manufacturing

Ady Rayyan (Universitas Dian Nuswantoro)

Jupiter: Publikasi Ilmu Keteknikan Industri, Teknik Elektro dan Informatika
Vol. 4 No. 4 (2026): Jupiter: Publikasi Ilmu Keteknikan Industri, Teknik Elektro dan Informatika.

The increase in production targets at NISHITANI Co. Ltd. from 4,500 to 5,700 units per shift demanded a smooth material flow. Initial conditions showed random Work-in-Process (WIP) placement triggering motion waste and transportation delays of 38 seconds per cycle. This study aimed to optimize facility layout and material handling using a Lean Manufacturing approach to reduce transfer time and meet capacity targets. The method combined route mapping using Spaghetti Diagrams, time studies, and computational simulation (JaamSim) to validate interventions. The layout implementation consolidated WIP areas, transforming a zigzag path into a straight-line flow. The results showed a decrease in material travel distance from 38 meters to 10 meters, and a reduction in transportation time from 38 seconds to 10 seconds per cycle. The use of batching transport trolleys was implemented to reduce the frequency of manual transfer. This layout and material handling intervention was able to consistently meet the target production flow rate.