Implement the Group Technology approach

Oct 13, 2025 by talynt.org 93 views

Re-design of Facilities at PT. Apindowaja Effective Persada with Group Technology Approach

Introduction

PT. Apindowaja Effective Persada is a manufacturing company that specializes in producing spare parts for machines in the palm oil industry. Located in Medan, North Sumatra, the company produces a wide range of spare parts, including mainshafts, cones, cone guides, pulleys, hydraulic cylinders, intermediate gears, gearboxes, protect nuts, screw worms, and others. Despite its focus on producing high-quality spare parts, the company faces several challenges in its production process. One of the main issues is the similarity of the form and process of spare parts production, which leads to high moments of material transfer and irregularity in production flow. This results in a decrease in operational efficiency and reduces the effectiveness of the flow of materials in the factory.

The Need for Re-design

The current machine settings at PT. Apindowaja Effective Persada use the process (process layout) approach, which is based on the similarity of functions. However, this approach has several limitations. The similarity of the form and process of spare parts production causes high moments of material transfer and irregularity in production flow. This results in a decrease in operational efficiency and reducing the effectiveness of the flow of materials in the factory. To overcome this problem, the company needs to re-design the location of the facilities, especially in the production department.

Group Technology Approach and Blocplan Method

One approach that can be applied to re-design the facilities at PT. Apindowaja Effective Persada is the Group Technology (GT) approach. This approach focuses on grouping products based on the similarity of their processes and characteristics. By implementing group technology, it is expected to reduce the moment of material transfer and increase the flow of production processes. In addition to the GT approach, the company also implements the Blocplan method. This method serves to redesign the factory layout by considering the closeness between various production facilities. With this method, companies can minimize distance between work stations and speed up the overall production process.

Implementation of Rank Order Clustering (ROC)

In re-designing the location of the facility, the Rank Order Clustering (ROC) method is used to identify product groups based on processing frequencies. By using a ROC, companies can group similar spare parts, so that the arrangement of machinery and production equipment can be done more effectively. The ROC method is a useful tool for identifying product groups and arranging machinery and production equipment in a way that minimizes material transfer and maximizes production flow.

Results of the Re-design

From the results of the calculations carried out, it is known that the rearrangement of the facility of the facility results in a decrease in the moment of transfer of materials to 39.6%. In addition, the application of the Blocplan algorithm shows the value of closeness between facilities of 0.45. This value indicates that the new layout is more efficient and provides better flow of materials in the factory.

Positive Impact on the Production Process

The layout of the proposal produced through this approach not only reduces the moment of displacement, but also shortens the time of the process of working on the entire spare parts. This certainly has a positive impact on company productivity and can increase competitiveness in the market. With better settings, employees can work more efficiently, and stopping time production can be minimized.

Conclusion

In conclusion, the re-design of the facility with the Group Technology approach supported by the ROC and Blocplan methods at PT. Apindowaja Effective Persada is the right solution to improve production efficiency and effectiveness. With this step, companies can meet market demand more optimally, as well as improve service quality to customers. The implementation of the GT approach and the ROC and Blocplan methods has shown significant results in reducing material transfer and increasing production flow. This approach can be applied to other manufacturing companies that face similar challenges in their production process.

Recommendations

Based on the results of this study, the following recommendations can be made:

Implement the Group Technology approach: The GT approach is a useful tool for grouping products based on the similarity of their processes and characteristics. By implementing this approach, companies can reduce material transfer and increase production flow.
Use the Rank Order Clustering (ROC) method: The ROC method is a useful tool for identifying product groups based on processing frequencies. By using this method, companies can group similar spare parts and arrange machinery and production equipment in a way that minimizes material transfer and maximizes production flow.
Apply the Blocplan algorithm: The Blocplan algorithm is a useful tool for redesigning the factory layout by considering the closeness between various production facilities. By applying this algorithm, companies can minimize distance between work stations and speed up the overall production process.

Future Research Directions

This study has shown the effectiveness of the Group Technology approach and the ROC and Blocplan methods in improving production efficiency and effectiveness. However, there are several areas that require further research. Some of these areas include:

Applying the GT approach to other industries: The GT approach has been shown to be effective in the manufacturing industry. However, its application to other industries, such as the service industry, requires further research.
Developing new methods for identifying product groups: The ROC method is a useful tool for identifying product groups based on processing frequencies. However, new methods for identifying product groups are required to improve the accuracy of the GT approach.
Applying the Blocplan algorithm to other factory layouts: The Blocplan algorithm is a useful tool for redesigning the factory layout by considering the closeness between various production facilities. However, its application to other factory layouts requires further research.

Limitations of the Study

This study has several limitations. Some of these limitations include:

Limited scope: This study was limited to the manufacturing industry and did not consider other industries, such as the service industry.
Limited data: The data used in this study was limited to the production process of PT. Apindowaja Effective Persada and did not consider other factors that may affect production efficiency and effectiveness.
Limited methodology: The methodology used in this study was limited to the Group Technology approach and the ROC and Blocplan methods. Other methodologies, such as the Total Productive Maintenance (TPM) approach, were not considered.

Conclusion

Q: What is Group Technology (GT) approach?

A: The Group Technology (GT) approach is a method of grouping products based on the similarity of their processes and characteristics. This approach aims to reduce material transfer and increase production flow by grouping similar products together.

Q: What is the Rank Order Clustering (ROC) method?

A: The Rank Order Clustering (ROC) method is a tool used to identify product groups based on processing frequencies. This method helps to group similar products together and arrange machinery and production equipment in a way that minimizes material transfer and maximizes production flow.

Q: What is the Blocplan algorithm?

A: The Blocplan algorithm is a tool used to redesign the factory layout by considering the closeness between various production facilities. This algorithm helps to minimize distance between work stations and speed up the overall production process.

Q: What are the benefits of re-designing facilities with the Group Technology approach?

A: The benefits of re-designing facilities with the Group Technology approach include:

Reduced material transfer
Increased production flow
Improved operational efficiency
Reduced production time
Improved competitiveness in the market

Q: What are the limitations of the Group Technology approach?

A: The limitations of the Group Technology approach include:

Limited scope (only applicable to manufacturing industry)
Limited data (only applicable to specific production process)
Limited methodology (only applicable to specific factory layout)

Q: How can the Group Technology approach be applied to other industries?

A: The Group Technology approach can be applied to other industries by adapting the methodology to the specific industry and production process. For example, in the service industry, the GT approach can be used to group similar services together and arrange resources in a way that minimizes material transfer and maximizes production flow.

Q: What are the future research directions for the Group Technology approach?

A: The future research directions for the Group Technology approach include:

Applying the GT approach to other industries
Developing new methods for identifying product groups
Applying the Blocplan algorithm to other factory layouts

Q: What are the recommendations for implementing the Group Technology approach?

A: The recommendations for implementing the Group Technology approach include:

Implementing the GT approach
Using the Rank Order Clustering (ROC) method
Applying the Blocplan algorithm

Q: What are the conclusions of this study?

A: The conclusions of this study are that the re-design of the facility with the Group Technology approach supported by the ROC and Blocplan methods at PT. Apindowaja Effective Persada is the right solution to improve production efficiency and effectiveness. With this step, companies can meet market demand more optimally, as well as improve service quality to customers.

Q: What are the implications of this study?

A: The implications of this study are that the Group Technology approach can be applied to other manufacturing companies that face similar challenges in their production process. This approach can help to improve production efficiency and effectiveness, and increase competitiveness in the market.

Q: What are the future implications of this study?

A: The future implications of this study are that the Group Technology approach can be applied to other industries, such as the service industry, and can help to improve production efficiency and effectiveness in those industries.