Silviatul Afdhilah (1), Rusindiyanto Rusindiyanto (2)
General Background: Efficient facility layout is essential for small food industries because repeated production flows require smooth material movement between workstations. Specific Background: A tofu home industry in Sidoarjo processes approximately 300 kg of soybeans per day, or about 19 batches, with daily output reaching around 6,156 tofu pieces, yet the initial layout created long and repeated movement between several workstations. Knowledge Gap: Previous studies have applied Systematic Layout Planning, Blocplan, Activity Relationship Chart, Activity Relationship Diagram, and ProModel separately or in different production systems, while their integrated use for tofu home industry layout design remains limited. Aims: This study aimed to redesign the tofu production facility layout using Systematic Layout Planning supported by Blocplan and ProModel simulation. Results: Blocplan generated 20 layout alternatives, and layout alternative 1 from the tenth iteration was selected with an R-score of 0.86, Adjacency Score of 0.49, and Relative Distance Score of 561. The selected layout decreased total movement distance from 1,182.12 m to 1,103.73 m, with 6.63% efficiency, and decreased total movement time from 3,901 seconds to 3,634.52 seconds, with 6.83% efficiency. ProModel simulation also showed that system completion time decreased from 5.24 hours to 4.59 hours, while blocked time decreased from 75.21 minutes to 52.76 minutes. Novelty: This study integrates SLP, Blocplan, and ProModel in one framework for designing, selecting, and dynamically evaluating tofu home industry layout alternatives. Implications: The proposed layout supports shorter movement paths, lower handling time, fewer flow barriers, and more balanced workload distribution.
Highlights:
Keywords: Facility Layout, Material Handling, Promodel, Systematic Layout Planning, Tofu Home Industry
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