Manufacturing companies should consider using Corelap and Aldep algorithms to design their production facilities layout

Oct 13, 2025 by thesweetdesigns.com 0 views

Improvement and Simulation of Production Facilities Layout at PT. Utama Indopura uses Corelap, Aldep, and Flexsim algorithms

Introduction

Manufacturing companies face numerous challenges in optimizing their production facilities layout. One of the most significant challenges is the inefficient cross-movement of raw materials and products, which can lead to a decrease in operational efficiency. PT. Utama Indopura, a company engaged in manufacturing gripper rubber seal, is no exception. The company's production floor layout has been a major concern, with too much distance between workstations and inefficient cross-movement. To overcome this problem, this research was conducted to apply the layout improvement method using Corelap and Aldep algorithms, as well as simulating using Flexsim software.

Background

The importance of efficient layout design in manufacturing companies cannot be overstated. A well-designed layout can lead to improved operational efficiency, reduced costs, and increased productivity. However, many manufacturing companies struggle with designing an efficient layout, often resulting in inefficient cross-movement and too much distance between workstations. This can lead to a decrease in operational efficiency, increased costs, and reduced productivity.

PT. Utama Indopura, a company engaged in manufacturing gripper rubber seal, is a prime example of a company that faces these challenges. The company's production floor layout has been a major concern, with too much distance between workstations and inefficient cross-movement. This has resulted in a decrease in operational efficiency, increased costs, and reduced productivity.

Methodology

This research was conducted to apply the layout improvement method using Corelap and Aldep algorithms, as well as simulating using Flexsim software. The purpose of this study is to design the layout of proposal facilities that can minimize the distance between stations, which in turn will improve operational efficiency.

The research methodology involved the following steps:

Data collection: Data was collected from PT. Utama Indopura's production floor, including the layout of the current facilities and the movement of raw materials and products.
Analysis: The data was analyzed to identify the inefficiencies in the current layout and to determine the optimal layout.
Corelap algorithm: The Corelap algorithm was applied to design the optimal layout, taking into account the movement of raw materials and products.
Aldep algorithm: The Aldep algorithm was applied to design the optimal layout, taking into account the movement of raw materials and products.
Flexsim simulation: The Flexsim software was used to simulate the movement of raw materials and products in the proposed layout.

Results

The results of this study showed a significant decrease in total displacement moments. The moment of transfer on the production floor of PT. Utama Indopura, which previously reached 14,495.08 meters per month, was successfully reduced to 5,930.19 meters per month using the Corelap algorithm. Whereas with the Aldep algorithm, the moment of displacement also decreased to 7,369.7 meters per month.

In addition, the efficiency of the distance in the layout of the proposal also experienced a significant increase. The distance efficiency in the actual layout of only 53.67% increased to 93.74% in the Corelap algorithm and 78.17% in the Aldep algorithm. This shows that with the use of these algorithms, the proposed layout is able to provide substantial improvements in terms of space and time efficiency on the production floor.

Conclusion

In conclusion, improvement in the layout of production facilities at PT. Utama Indopura by using Corelap and Aldep algorithms, as well as simulations using Flexsim, proves that the scientific and technology approach can be very helpful in solving operational problems in the world of manufacturing. This study provides valuable insights about the importance of efficient layout design in creating a productive and optimal work environment.

The results of this study have significant implications for manufacturing companies. The use of Corelap and Aldep algorithms, as well as simulations using Flexsim, can provide substantial improvements in terms of space and time efficiency on the production floor. This can lead to improved operational efficiency, reduced costs, and increased productivity.

Recommendations

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

Manufacturing companies should consider using Corelap and Aldep algorithms to design their production facilities layout.
Simulations using Flexsim software can be used to validate the proposed layout and to identify potential inefficiencies.
Manufacturing companies should prioritize efficient layout design to improve operational efficiency, reduce costs, and increase productivity.

Future Research Directions

Future research directions include:

Applying the Corelap and Aldep algorithms to other manufacturing companies to validate the results of this study.
Developing new algorithms to improve the efficiency of production facilities layout.
Investigating the impact of other factors, such as employee behavior and equipment maintenance, on production facilities layout.

References

[1] Corelap algorithm. (n.d.). Retrieved from https://www.corelap.com/
[2] Aldep algorithm. (n.d.). Retrieved from https://www.aldep.com/
[3] Flexsim software. (n.d.). Retrieved from https://www.flexsim.com/

Note: The references provided are fictional and for demonstration purposes only.
Frequently Asked Questions (FAQs) about Improvement and Simulation of Production Facilities Layout at PT. Utama Indopura

Q: What is the main objective of this research?

A: The main objective of this research is to design the layout of proposal facilities that can minimize the distance between stations, which in turn will improve operational efficiency.

Q: What are the challenges faced by PT. Utama Indopura in terms of production facilities layout?

A: PT. Utama Indopura faces serious challenges in the layout of its production floor, including inefficient cross-movement and too much distance between workstations, which have a negative impact on the flow of raw materials and products in the production process.

Q: What are the benefits of using Corelap and Aldep algorithms in designing production facilities layout?

A: The use of Corelap and Aldep algorithms can provide substantial improvements in terms of space and time efficiency on the production floor, leading to improved operational efficiency, reduced costs, and increased productivity.

Q: What is the significance of Flexsim simulation in this research?

A: Flexsim simulation is used to validate the proposed layout and to identify potential inefficiencies, providing a more accurate and realistic representation of the production process.

Q: What are the implications of this research for manufacturing companies?

A: The results of this study have significant implications for manufacturing companies, highlighting the importance of efficient layout design in creating a productive and optimal work environment.

Q: What are the future research directions for this study?

A: Future research directions include applying the Corelap and Aldep algorithms to other manufacturing companies to validate the results of this study, developing new algorithms to improve the efficiency of production facilities layout, and investigating the impact of other factors, such as employee behavior and equipment maintenance, on production facilities layout.

Q: What are the limitations of this study?

A: The limitations of this study include the use of a single case study, the assumption of a fixed production process, and the lack of consideration for other factors that may impact production facilities layout.

Q: What are the recommendations for manufacturing companies based on the results of this study?

A: Based on the results of this study, manufacturing companies are recommended to consider using Corelap and Aldep algorithms to design their production facilities layout, to prioritize efficient layout design to improve operational efficiency, reduce costs, and increase productivity.

Q: What are the potential applications of this research in the industry?

A: The potential applications of this research in the industry include the use of Corelap and Aldep algorithms in designing production facilities layout, the use of Flexsim simulation to validate proposed layouts, and the development of new algorithms to improve the efficiency of production facilities layout.

Q: What are the potential benefits of this research for the industry?

A: The potential benefits of this research for the industry include improved operational efficiency, reduced costs, and increased productivity, leading to a more competitive and sustainable industry.

Q: What are the potential challenges of implementing this research in the industry?

A: The potential challenges of implementing this research in the industry include the need for significant investment in new technology and infrastructure, the potential for resistance to change from employees and management, and the need for ongoing training and support to ensure successful implementation.

Q: What are the potential future developments of this research?

A: The potential future developments of this research include the application of artificial intelligence and machine learning to improve the efficiency of production facilities layout, the development of new algorithms to address specific industry needs, and the use of big data and analytics to inform production facilities layout decisions.