Facility Layout Redesign Using BLOCPLAN Algorithm to Minimize Material Handling Distance and Cost in Black Tea Production Facility
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Abstract
Purpose – This study aims to redesign the production facility layout at PTPN 1 Regional 5 Wonosari Tea Plantation, Malang, using the BLOCPLAN algorithm, with the primary objective of minimizing material transfer distance and Material Handling Cost (MHC) across nine inter-departmental material flows in a black tea Crushing, Tearing, and Curling (CTC) production facility.
Methodology – Data collection employed three methods: direct observation (facility dimensions and inter-departmental distances); document review for material flow frequency data to construct the From-To Chart (FTC); and structured interviews with field supervisors to establish the Activity Relationship Chart (ARC). The existing layout was evaluated using the Rectilinear Distance formula to calculate total MHC. The BLOCPLAN algorithm was executed with dual FTC and ARC inputs, generating 20 layout iterations from which the five layouts with the highest Adjusted R-Score were selected. The best proposed layout (LU5) was identified and evaluated through rectilinear distance calculation and MHC computation for all nine material flows, then compared directly against the existing layout, supplemented by scaled grid and final floor plan visualizations.
Findings – The proposed BLOCPLAN LU5 layout achieved a total material transfer distance of 105.5 meters—a 70.75% reduction from the existing 360.7 meters—and a total daily MHC of IDR 33,251,558.71, a 28.89% reduction from the existing IDR 46,782,284 (daily savings of IDR 13,530,725.29). The most critical flow, D1–D2 (Fresh Leaf Receiving to Withering), was reduced from 150 meters to 16 meters (89.33%), cutting its daily MHC from IDR 9,866,374 to IDR 1,052,412.48. The BLOCPLAN layout successfully eliminated backtracking and aligned departments with the sequential CTC production process.
Originality – This study provides an original contribution by applying the BLOCPLAN hybrid algorithm to a black tea CTC processing facility. The research presents a comprehensive comparison of distance and MHC changes, supplemented by a scaled departmental grid visualization and the final recommended floor plan, offering a granular and visually grounded analysis that demonstrates which specific inter-departmental flows drive the greatest efficiency gains.
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