IMPROVEMENT OF FACILITY LAYOUT FOR MANURING PROCESS IN AN OIL PALM PLANTATION: A SIMULATION-BASED STUDY

Abstract

Facility layout plays a crucial role in operational efficiency by influencing material flow, labor utilization, and productivity. Although layout optimization has been widely applied in manufacturing, its implementation in plantation operations, particularly in oil palm manuring, remains limited. This study evaluates the existing facility layout for the manuring process from the workshop to the field, which relies heavily on manual material handling, resulting in prolonged handling time, potential worker idle time, and inefficient use of labor and equipment. The main objective of this paper is to assess the current layout and develop an improved facility layout that enhances operational efficiency and safety, with its performance verified through simulation analysis. On-site observations and time-study data were collected from workers involved in the manuring process to represent actual operating conditions. The existing and proposed layouts were developed using SketchUp and evaluated through discrete-event simulation in FlexSim to analyze worker movement, cycle time, and labor utilization. The proposed layout integrates the Hasrul Fertilizer Lift (HFL), a mechanized system designed to reduce manual fertilizer handling. Simulation results indicate improved operational performance through increased worker utilization and reduced operational cycle time. These findings demonstrate that the proposed layout improves workflow efficiency, reduces manual handling, and enhances labor utilization. This study provides practical guidance for plantation managers and demonstrates the value of simulation-based facility layout optimization for improving oil palm manuring operations.