Proceedings of the 3rd South American International Industrial Engineering and Operations Management

Conference, Asuncion, Paraguay, July 19-21, 2022

Computerized Relative Allocation of Facilities Techniques

(CRAFT) Algorithm Method for Redesign Production
Layout(Case Study: PCL Company)
Atika Nabila
Student at Industrial Enggnering
Universitas Islam Negeri Sultan Syarif Kasim Riau
[email protected]

Muhammad Isnaini Hadiyul Umam, Suherman, Anwardi, Vera Devani, Nazaruddin,

Muhammad Rizki
Assistant Professor at Industrial Enggnering
Universitas Islam Negeri Sultan Syarif Kasim Riau
[email protected], [email protected], [email protected],
[email protected], [email protected], [email protected]

Abstract
PCL Company is a Small - Medium Enterprises industry engaged in the printing sector in Indonesia. The PCL
company's production floor's layout problem is crossing production lines. It can hinder workers from doing
production, and the long-distance between machines creates an alternating current which causes time and energy to
be wasted in moving materials. Workers are hampered and make long distances. This research aims to redesign the
production layout to improve the production flow and minimize material handling distances in the production
process in Printing. Data processing is carried out using (CRAFT). The CRAFT method is done by swapping areas
in the initial layout to find a better solution based on the Activity Relationship Chart (ARC). The area exchange on
the ARC will lead to a layout close to the minimum material handling distance. The result of the calculation of
material handling for the prefix layout is 20,432 meters. Alternative Layout 1 has a material transfer distance of
5,849 meters, while alternative 2 has a material transfer distance of 7,095 meters. Alternative layout one was chosen
as the best proposal because it has the smallest total material transfer distance. After that, the selected alternative
proposed layout is used for the initial layout in the craft method processing. After processing the data using the
CRAFT method, the optimal proposed layout is obtained.

Keywords
Activity Relationship Chart (ARC), Alternative Layout, Computerized Relative Allocation Facilities Technique
(CRAFT), Layout design, Material Handling.

1. Introduction
One way to increase production productivity is to improve the components of production machines or the layout of
factory facilities. The layout of the settings is related to the change from input to output. An effective and efficient
layout is demonstrated by no backtracking, less overall material transfer, and no bottlenecks in the process. An
effective and efficient layout helps reduce production cycle times, idle time, bottlenecks or material handling time
and can increase production output, so the layout of production facilities must be done to help smooth the production
process.

PCL Company is an industry in Indonesia for Small and Medium Enterprises engaged in the printing sector. The
printery has some machinery, including glue binding, cutting, and GTU printing tools. Every month, a defined
production goal is established for custom chart items. With a typical processing time of 10 minutes for each bespoke
folder sheet, it processes 2500 sheets every month. Based on a direct inspection of the printing location, several
problems were found, which can be seen in Figure 1, a layout image of PCL Company that there are still production
line crossings that can be seen hindering workers in carrying out production. The distance between machines is far

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
Conference, Asuncion, Paraguay, July 19-21, 2022

so that it creates alternating currents. This causes time and energy to be wasted in moving materials, hindering
workers and making longer distances. The next problem is the pile of leftover material, the buildup occurs on the
production floor on the blue line on the layout, which causes the production floor to become narrow, and the
operator is less flexible in carrying out production activities

Figure 1. Initial Layout of PCL Company

Due to the condition of the production floor and the long distances required for material handling, it is necessary to
redesign the layout at the printing facility continuously. This redesign is necessary based on Appel's (1990) Principle
of Minimum Distance, which dictates that the layout be as close to one another as possible to reduce material
handling distances. One method that can be used to overcome material handling problems in the PCL Company
production process is the CRAFT (Computerized Relative Allocation Facilities Technique) method. The use of this
method is because the CRAFT method is a method used to find improvements and optimum design by making
improvements to the layout gradually. In addition, CRAFT evaluates the layout by exchanging departmental
locations. Research by Yuliana, et al (2017) proves that the design of the facility layout using the CRAFT method
can reduce material handling distances

1.1 Objectives
The goal of this study is to layout the PCL Company's production floor more efficiently than it currently is. In
addition, the layout design is carried out to enhance the production flow that traverses the floor and further reduce
the distance of material handling on the production floor of brilliant sustainable Printing.

2. Literature Review
Facility layout design is one factor that affects a company's performance in supporting production. Businesses today
face increasingly difficult challenges. To stay competitive, they need to improve efficiency (Suhardi et al. 2019).
Facility layout planning involves physically arranging all the factors of production that improve the production
system so that it can be appropriate and efficient in following the organization's strategic objectives. As part of the
business operational strategy, the layout is considered one of the most important design decisions (Gosende et al.
2021).

A good facility layout is directly related to the material handling cost. Therefore, the objective function value used
to evaluate the layout configuration is also related to the movement between departments. Some distance existing
measurements, The rectilinear distance consists of the absolute distance between the two reference points of the
section on the x and y axes. On the contrary, the Euclidean distance is the shortest diagonal distance (Kim and chae
2019).

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
Conference, Asuncion, Paraguay, July 19-21, 2022

Arc is a pattern of material that can be calculated quantitatively by comparing the degree of closeness between each
other's areas (departments) (kolo et al. 2021). An Activity Relationship Chart (ARC) is needed to convert quality
into quantity. The ARC setting is determined using the relationship level and interdepartmental reasons. ARC is
varied by providing a code based on values and reasons for inter-departmental relationships.

FTC or travel chart is commonly used in manufacturing processes and plant and material planning. The chart is
useful when there is a lot of material movement in an area (Chaerul et al. 2021). An activity Relationship chart is a
simple technique for planning a facility or department layout based on the relationship between activities. Activity
relationship charts are often presented as "qualitative" assessments and tend to be based on subjective judgments
(Tampubolon et al. 2020).

Computerized Relative Allocation of Facilities Techniques (CRAFT) is an improvement program that aims to
optimize the design by progressively improving the layout. CRAFT assesses facilities with interchangeable
departmental locations. Processing of the CRAFT method is carried out using the winsQSB software. The type of
exchange carried out is the exchange of two departments using a distance measurement type, namely rectilinear
distance. The reason for using this type is because the initial layout used has been redesigned from the initial layout,
so it only requires slight improvements to get an optimal layout (Siska and Risman 2017).

According to Yuliana et al. (2017) the principle of departmental exchange based on the CRAFT method must meet
one of the following three conditions, namely:
1. The departments must have the same border.
2. Departments must be the same size.
3. The department must have both borders - the same border on all three departments.

The stages in the CRAFT method, according to Yuliana et al. (2017):

1. Make a chart of the relationship between activities/ARC. The activity relationship chart is intended to determine
the close relationship between departments.
2. Conduct departmental exchanges based on the /ARC activity relationship chart. According to the CRAFT
method, exchanges between departments meet at least one of the three principal requirements of the
departmental exchange.
3. Calculate the midpoint of each block. Departmental changes due to exchange will change the central coordinates
of the department concerned. The central coordinates of the non-rectangular departments are partitioned into
rectangular partitions, so the calculation process is obtained.
4. Calculate the floor area of each block.
5. Create an FTC distance chart.

3. Methods
The research was conducted at PCL Company located on Jl. KH. Ahmad Dahlan No. 43. Central, Sukajadi district,
Pekanbaru City. This research applies the CRAFT algorithm with the help of WinQSB 2.0 software. The following
is a chart of the research stages from beginning to end:

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
Conference, Asuncion, Paraguay, July 19-21, 2022

Star

Preliminar y studies

Study of litera ture

Identif ication of problems

Formulation of the problem

Resear ch purposes

Data collection
1. SME Profile
2. Work Area
3. Production Proc ess
4. Average Produc tion Time
5. Machine Used
6. Production Targe t

Data pr ocessing
1.Creating Wor kmaps and Flowcha rts
2. Deter mining the Dis tance Between Stations and
Material Handling
3. Create ARC, ARD, and AAD
4. Sele cting the Pref err ed AAD
5. Material Handling Initia l Condition
6. From to Chart Proposed Conventional M ethod
Sele cted
7. Layout of the Selected M ethods of the CRAFT
Algorithm
8. Compar ison of Pr efix La yout and CRAFT

Analysis

Finis

Figure 2. Flowchart Research

The explanation of Figure 2 is as follows:
1. This preliminary study is the initial stage of research, the data obtained in the form of data to support such as
prefix layout data, average operating time, and material handling distances, planning and layout design of PCL
Company facilities
2. Contains reviews and explanations of useful theories to help solve problems in the planning and design of PCL
Company facilities
3. Based on data from research and theoretical foundations, the problems that can be seen are the distance between
machines that are far so that material handling is large. Crossover occurs during production. The distance
between machines is far so that it creates an alternating current which causes time and energy to be wasted in
material transfer
4. The formulation of the problem obtained is how to redesign the layout of the production facility to minimize
material handling on the production floor of PCL Company using the CRAFT method.
5. Based on the results of the preliminary survey conducted, it is known that the main issue of this survey is how to
take steps to get the optimal layout proposal for the production floor
6. Data collection for this research was conducted using interview techniques and direct measurements in the field.
Interviews are conducted with employers, employees, and other parties who can provide information orally or in
writing
7. The resulting data is used as auxiliary data and initial data in designing the layout of the PCL Company facility
using the Craft Method (Computerized Relative Allocation Facilities Technique).
8. Data analysis in this study is defined, including basic data analysis, human resource planning analysis, spatial
planning requirements analysis, operation alignment, up to calculations, length of proposed processing
arrangement, and analysis results comparing the prefix layout and the selected layout proposal of the CRAFT
method.

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
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9. The final stage is concluding and making recommendations. The conclusions drawn include the results of the
design and analysis of the survey results. This conclusion must be adapted to the research objectives. The
suggestions given should be constructive for the next level of improvement

4. Data Collection
In this study, the company took part, and PCL Company conducted direct observations of the company's production
data, production capacity, number of machines, machine sizes, production sites, and supporting data, among other
data. Additionally, some statistics were directly obtained from the business. In this study, the company took part,
and PCL Company conducted direct observations of the company's production data, production capacity, number of
machines, machine sizes, production sites, and supporting data, among other data. Additionally, some statistics were
directly obtained from the business.

4.1 Production Target

The following is the production data of PCL Company in 1 month in the process of making a Custom folder. (Table
1)
Tabel 1. Production Target
Date Day Order
1 February 2022 Friday 125
4 February 2022 Monday 100
6 February 2022 Wednesday 125
9 February 2022 Thursday 120
10 February 2022 Friday 100
13 February 2022 Monday 200
15 February 2022 Tuesday 50
17 February 2022 Thursday 200
22 February 2022 Monday 200
24 February 2022 Wednesday 200
26 February 2022 Friday 100
30 February 2022 Monday 250

4.2 Production Flow

The process of creating a custom chart is as follows: (Figure 3)
1. Consumers place orders at the cashier desk
2. Customer orders are designed on the computer
3. The product will be printed on a GTU printer
4. The product is cut and trimmed in the cutting machine
5. Products are glued and put together using a glue machine
6. Products are placed in the warehouse.

Figure 3. Production Flow

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
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5. Results and Discussion

5.1 Work Station Planning

Workstations are one of the determining factors for a company's productivity. A workstation includes space for
equipment, materials, and people like all other facilities. Specific space requirements for the operator and material
handling can be determined based on the method of operation. The following is a recapitulation of the workstation
planning for machines on the production floor: (Table 2)
Table 2. Recapitulation of Production Floor Area
Station Machine Total
Name size Machine Operator Machine
Stacking total machine
Level area area area
P L area machine area
(m2) (m2) (m2)
(m) (m) (m2)
GTU
Printing 2,5 1 2,5 0,142 0,412 3,804 1 5,7
Machine
Production
Cutting
Floor 2 1 1,2 0,142 0,412 3,304 1 4,96
machine
Glue
0,74 0,51 10 0,142 0,27 1,682 1 2,53
Machine
Total 5,24 2,51 13,7 0,426 0,554 8,79 3 13,19

5.2 Activity Linkage Planning

ARC measures flow qualitatively using the value of the close relationship between activities at PCL
Company.(Figure 4)

Figure 4. Activity Relationship Chart

After the preparation of the ARC, the next step is the preparation of the template block. The following is a PCL
enterprise block template plan (Figure 5)

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
Conference, Asuncion, Paraguay, July 19-21, 2022

A=0 E=2 A=0 E = 1,3 A=4 E=2 A=0 E=3

X=0 X=0 X =0 X =0

1 2 3 4
Printer GTU Cutting Machine Glue Machine Assembly Area

U=4 U=4 U=0 U = 1,2

I=0 O=3 I=0 O=0 I=0 O=1 I=0 O=0

Figure 5. Block Template Plan

The name ARD is also used to determine the extent of the relationship between activities or activities. The planning
area relationship diagram (ARD) of the entire PCL Company is as follows (Figure 6)

A=0 E=2

X=0

1
Printer GTU

U=4

I=0 O=3
A=0 E=3 A=4 E=2 A=0 E = 1,3

X =0 X =0 X=0

4 3 2
Assembly Area Glue Machine Cutting Machine

U = 1,2 U=0 U=4

I=0 O=0 I=0 O=1 I=0 O=0

Figure 6. ARD

From the next ARD, the AAD or departmental arrangement is made using the actual dimensions that have been
scaled, as shown in Figure 7

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Proceedings of the 3rd South American International Industrial Engineering and Operations Management
Conference, Asuncion, Paraguay, July 19-21, 2022

Printer GTU

Assembly Glue Cutting

Area Machine Machine

Figure 7. AAD

5.3 Material Handling Calculation

The main objective of material handling planning is to reduce the displacement distance. In addition, material
handling is very influential on the operation and design of the implemented facilities. After doing the Activity
Linkage Planning, the next step is to calculate material handling from to chart as shown in Table 3:
Table 3. FTC

Factory: PCL Company Date: May 25, 2022

From
A B C D Jumlah
To
A

B 28,4 28,4

C 38,4 38,4

D 43,2 43,2

Jumlah 28,4 38,4 43,2 100

The next stage compares the smallest alternative in the calculation of material handling to chart for use in the
CRAFT method. The following Table 4 summarises the initial and proposed form to chart layout calculations.
Table 4 Comparison of material handling distance

Material Handling
Product Initial
Alternative 1 Alternative 2
Layout

Custom Folder 20,432 5,849 7,095

From Table 4, it can be seen that the comparison of the initial handling distance layout and the proposed alternative
1 and 2. Where, the total displacement distance for the initial layout is 20,432 m from the material handling
comparison so that alternative layout proposals 2 on conventional techniques are used as the initial layout of the
layout design using the method CRAFT

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5.4 Processing CRAFT Method

Processing of the CRAFT method aims to get an effective proposal layout and efficiently by exchanging different
departments have the same area between the same department with others to reduce the total moving distance.(
Figures 8 & 9)

Figure 8. Initial Layout

Figure 9. Final Iterate

After solving and analyzing, the optimal proposed layout is obtained, namely until the 1st iteration. Where up to this
point, no more iterations can be done, so this layout is what serves as a proposed layout in the PCL Company, as in
Figure 10

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Figure 10. PCL Company Proposal Layout

6. Conclusion
After processing, then an effective and efficient proposed layout is obtained. Layout redesign is essential to increase
productivity and reduce material handling distances. The material handling distance in the initial layout is 20,432 m.
In the alternative, one layout is 5.8 m and 7.09 m in alternative 2. Then alternative one is used as the initial layout in
the Winqsb application. It can be seen that after redesigning, the material handling becomes smaller, and after that,
data processing is done using CRAFT to get a more effective layout.

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Biography
Atika Nabila was born in Pekanbaru on June 23, 2000, The author's journey in the level of seeking knowledge has
followed formal education 2005 Entered State Elementary School 10 Pasaman, Year 2012 Entered Madrasah
Tsanawiyah Muhammadiyah Batu Bulat, 2015 Entered Madrasah Aliyah Negri 3 Tanah Datar in 2018 Registered as
a student of Sultan Syarif Kasim State Islamic University (UIN) Riau, Department of Industrial Engineering.

Muhammad Isnaini Hadiyul Umam is assistant professor at the Department of Industrial Engineering at Sultan
Syarif Kasim State Islamic University, Indonesia

Suherman is assistant professor at the Department of Industrial Engineering at Sultan Syarif Kasim State Islamic
University, Indonesia

Anwardi i is assistant professor at the Department of Industrial Engineering at Sultan Syarif Kasim State Islamic
University, Indonesia

Vera Devani is assistant professor at the Department of Industrial Engineering at Sultan Syarif Kasim State Islamic
University, Indonesia

Nazaruddin is assistant professor Industrial Engineering Departement at Sultan Syarif Kasim State Islamic
University, Indonesia

Muhammad Rizki is assistant professor Industrial Engineering Departement at Sultan Syarif Kasim State Islamic
University, Indonesia

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