Evaluation of Production Facility Layout to Minimize Backtracking: A Case Study of Green Tea Production at Factory X
DOI:
https://doi.org/10.33387/josae.v9i2.11821Keywords:
Facility layout, Green tea production, ARC, TCR, Line balancing, Production efficiencyAbstract
Facility layout plays a critical role in determining production efficiency, productivity, and the smoothness of material flow in manufacturing systems. This study aims to evaluate and improve the facility layout of a green tea factory at PT X to minimize backtracking and enhance production flow efficiency through the integration of Activity Relationship Chart (ARC), Total Closeness Rating (TCR), and line balancing methods. A quantitative descriptive approach was employed based on direct observation and interviews. The production system consists of seven main activities: raw material storage, sortation 1, roasting, cooling section, sortation 2, packing, and final storage. The initial layout condition indicates inefficient material flow, backtracking occurrences, a total idle time of 19 minutes per cycle, and a line efficiency of 55%. Based on ARC and TCR analysis, an alternative layout was developed by arranging facilities according to activity relationships and process sequence. Furthermore, the implementation of line balancing resulted in four workstations with reduced idle time of 1 minute per cycle and increased line efficiency to 96%. The proposed layout produces a more linear production flow, reduces unnecessary movement, and improves overall operational performance. The findings demonstrate that the integration of ARC, TCR, and line balancing is effective in optimizing facility layout and supporting a more efficient and productive production system.Downloads
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