Facility Layout Design Using Genetic Algorithm to Minimize the Waste of Transportation in Lean Manufacturing

Competition in the industry encourages improvement and optimization of the production line. The system to be achieved in industry is a lean system. Achieving a lean system or lean manufacturing allows the industry to perform its business effectively and optimally. This research aims to optimize the production line of one of the manufacturing industries in Indonesia using lean manufacturing. Lean manufacturing identified the non-value-added activity in the industry as waste. There are 3 tools used, which are Value Stream Analysis Tools (VALSAT), Process Activity Mapping (PAM), and Waste Relationship Matrix (WRM). VALSAT recommends PAM as a waste analysis tool. The average result of the non-value-added activity (NVA) in PAM based on activity is 47,4% and based on time is 8,47%. Waste with the highest weight as a result of WRM with a percentage of 20,03% is transportation. Waste of transportation can be eliminated by evaluating and optimizing the existing layout. In this study, the Genetic Algorithm (GA) was used to optimize the existing layout and obtain the Total Material Handling Cost (TMHC) savings of 12,3%.