Evaluation and Proposed Improvements to The Packaging Room Layout of PT. X Using the Activity Relationship Chart Method

PT. X is a food industry that produces various types of products, including ready-to-eat products. The products are packaged in a 6.5×5 m2 packaging room used for two types of packaging: small and large. Ideally, these two packaging processes should not be carried out simultaneously, but during peak season conditions, both must be implemented, leading to waste motion, cross-flow of work, and potential workplace accidents. This research aims to redesign the packaging space layout so that both packages can be in line and increase labour productivity. The method used is the Activity Relationship Chart (ARC) to design the new layout. Subsequently, cycle time and Euclidean distance were measured before and after the proposed improvements. The research results show that reducing the average time brought the 30 kg bulk WIP from 7.43 seconds to 4.54 seconds and decreased the transfer time from the small packaging machine to the metal detector from 8.90 seconds to 3.15 seconds. The Euclidean distance calculation also shows a decrease in worker travel distance at the small packaging (250 grams) and large packaging (1 kg) production stages. For small packaging, the distance decreased by 7% from the Bulk WIP Pallet to the Small Packaging Machine Platform and by 62% from the Small Packaging Machine to the Metal Detector, while one transfer path remained unchanged. For large packaging, all transfer paths experienced a decrease in distance, with percentages of 50%, 39%, and 23% respectively. Additionally, productivity increased from 22 kg/man hour before improvement to 28 kg/man hour after improvement.