Optimization of a tea processing plant layout : a case study of Pagilaran Ltd., Indonesia | |
| Author | Krisdiarto, Andreas Wahyu |
| Call Number | AIT Thesis no. AE-01-04 |
| Subject(s) | Tea trade--Indonesia Manufacturing processes--Indonesia Plant layout |
| Note | A thesis submitted in partial fulfillment of the requirements for the degree of Master of Engineering, School of Environment, Resources and Development |
| Publisher | Asian Institute of Technology |
| Series Statement | Thesis ; no. AE-01-04 |
| Abstract | Indonesia is one of the major tea producer in the world. Most of the tea produced in Indonesia is black tea. The Pagilaran Ltd. Indonesia, is one of the factory producing tea since 1922. As an export company, Pagilaran should compete with other companies in term of efficiency. The last reorganization of this factory was in 1964. Some new machines after that time have been placed in the existing layout. This study was aimed to optimize the processing plant layout in order to improve the tea processing. The machine layout in a dry-sorting processes is the most possible place to be optimized. The process involves many machines and material transports in this process are done manually. There are four tea powder quality processed in dry-sorting room, each of them follows different material flow among the machines. LAYOUT program in Quantitative System (QS) 2.0 was employed in this study to find a better layout. Number of flows between machines and initial layout were used as inputs for this program. After a better layout was proposed by this program, ProModel software was employed to model the dry-s01iing process. Models built were for each tea powder quality, in existing layout and in proposed layout. Simulations of dry-sorting process using ProModel give information of processing time for each tea powder quality. Six of seven model simulation result in positive mean or processing time using proposed layout were faster than using existing layout. There are: for 1st quality (faster by 2.0% ), for 2nd quality (by 5.0 %), 3rd quality-1st grade (by 3.2%), 3rd quality-2nd grade (by 1.4%), 4th quality- 2nd grade (by 5.8%), and for 'badag' quality (by 1.4%). Processing time of proposed layout that was longer than of existing layout for 4th-1st grade quality. In terms of weight, proposed layout give possibility to process those seven grade quality more by 14 kg, 37 kg, 16 kg, 7 kg, 19 kg, 10 kg, and -21 kg, respectively Apart from machine relocation, it is suggested to heap tea baggage properly in the aisle. As practically done by the worker, they heap the tea baggage in the aisle. It will narrow the aisles and obstruct the material flows resulting in slower material flows. |
| Year | 2001 |
| Corresponding Series Added Entry | Asian Institute of Technology. Thesis ; no. AE-01-04 |
| Type | Thesis |
| School | School of Environment, Resources, and Development (SERD) |
| Department | Department of Food, Agriculture and Natural Resources (Former title: Department of Food Agriculture, and BioResources (DFAB)) |
| Academic Program/FoS | Agricultural and Food Engineering (AE) |
| Chairperson(s) | Salokhe, V.M.; |
| Examination Committee(s) | Singh, Gajendra;Athapol N.;Nitin Afzulpurkar; |
| Scholarship Donor(s) | Asian Development Bank ; |
| Degree | Thesis (M. Eng.) - Asian Institute of Technology, 2001 |