ASSEMBLY LINE OPTIMIZATION USING LINE BALANCING APPROACH TO REDUCE TAKT TIME AND LEAD TIME IN ELECTRICAL COMPANY
By
Ivander Arisito Sudarnoto 11212098
BACHELOR‟S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 – Indonesia
August 2017
Ivander Arisito Sudarnoto STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Ivander Arisito Sudarnoto
_____________________________________________
Student Date
Approved by:
Dr. Tanika D. Sofianti, S.T.,M.T.
_____________________________________________
Thesis Advisor Date
Dr. Eng. Sumarsono, S.T.,M.T.,OCP
_____________________________________________
Thesis Co-Advisor Date
Dr. Ir. Gembong Baskoro, M.Sc.
_____________________________________________
Dean Date
ABSTRACT
ASSEMBLY LINE OPTIMIZATION USING LINE BALANCING APPROACH TO REDUCE TAKT TIME AND LEAD TIME IN ELECTRICAL COMPANY
By
Ivander Arisito Sudarnoto
Dr. Tanika D. Sofianti, S.T.,M.T., Advisor Dr. Eng. Sumarsono, S.T.,M.T.,OCP, Co-Advisor
SWISS GERMAN UNIVERSITY
This research based on the case study in PT.XYZ‟s PiX assembly line, is addressed how to optimize the manual assembly line by rebalancing the line in order to reduce bottleneck and idle time and to increase line efficiency, so that PiX team can reach its production target and PT.XYZ can fulfil the customer‟s demand. Based on observation, the flow process didn‟t run smoothly and it caused unbalanced line and the accumulation of WIP. Therefore, in this research line balancing problem is solved using heuristic approaches and what if analysis to find the best solution by reallocating work element or tasks of workstation so that the number of workstation can be optimized. The methods are Largest Candidate Rule, Incremental Utilization Heuristic, and What if Analysis. The analysis of those methods are compared then translated to system modelling simulation using Tecnomatix Plant Simulation as the result of this research.
Keywords: Line Balancing, Assembly Line, Idle Time, Bottleneck, Largest Candidate Rule, Incremental Utilization Analysis, What if Analysis, Tecnomatix Plant Simulation
© Copyright 2017 by Ivander Arisito Sudarnoto
All rights reserved
DEDICATION
I dedicate this thesis work for my future self and my beloved parents:
Arisito Sudarnoto and Ernawati Heng
ACKNOWLEDGEMENTS
I owe my gratitude to all those people who have made this thesis possible and because of whom my graduate experience has been one that I will cherish forever.
Firstly and foremost I would like to thank my Lord Jesus Christ that has given me strength and infinite blessings during working of this thesis.
Special thanks to my parents, Arisito Sudarnoto and Ernawati Heng, and my older sister, Erlin, for giving me support and always encourage me with their best wishes.
I would like to express my deepest gratitude to my advisor, Dr. Tanika D. Sofianti, ST MT, and my co-advisor, Dr. Eng. Sumarsono, S.T.,M.T.,OCP, for the patience of correcting my writing, caring, and guidance to finish this project.
I also would like to thank Pak Adi Widiadi and Mas Ibnu Arpiansyah for giving me the opportunity to do this thesis in PT Panarub Industry and the responsibility of such an assignment in their PiX project. Without their support and information I would not be able to initiate and carry out this project.
All my best friends in Industrial Engineering 2013 especially Azizie, Nindya, and Damario who had helped and support me a lot when there were difficulties in study and this thesis. Thanks for the unforgettable and funny memories in four years. You guys will always be in my heart.
TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS... 6
TABLE OF CONTENTS ... 6
LIST OF FIGURES... 9
LIST OF TABLES... 10
CHAPTER 1 – INTRODUCTION ... 12
1.1 Background ... 12
1.2 Research Problems ... 13
1.3 Thesis Objectives ... 13
1.4 Thesis Scope and Limitation ... 13
1.5 Thesis Structure ... 14
CHAPTER 2 - LITERATURE REVIEW ... 15
2.1 Definition and Parameters ... 15
2.2 Overview of Assembly Line ... 18
2.3 Overview of Assembly Line Balancing ... 19
2.3.1Assembly Line Balancing Problem ... 21
2.3.2Objective of Line Balancing ... 25
2.3.3Line Balancing Method ... 27
2.4 Time Study ... 28
2.5 Lean Production... 29
2.5.1Value Added and Non-Value Added Operation ... 30
2.6 Manufacturing Plant Simulation ... 31
2.6.1Tecnomatix Plant Simulation ... 31
CHAPTER 3 – RESEARCH METHODS ... 35
3.1 Research Methodology ... 35
3.2 Problem Identification... 36
3.2.1Product Overview ... 36
3.2.2Field Observation ... 37
3.2.3Assembly Line Process ... 38
3.2.4Identify The Problem... 40
3.2.5Evaluation of Line Performance ... 40
3.3 Literature Review ... 42
3.4 Data Acquisition ... 42
3.4.1Time Study ... 42
3.5 Line Balancing... 44
3.6 Improvement Simulation ... 45
3.7 Analysis... 46
3.8 Conclusion ... 46
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 46
4.1 Data Acquisition ... 47
4.1.1Work Hours ... 47
4.1.2Product Forecast ... 47
4.1.3Assembly Line Capacity ... 49
4.1.4Design Time ... 50
4.1.5Assembly Chronology ... 52
4.1.6Process Flowchart ... 54
4.1.7Current Operation Time ... 57
4.2 Data Analysis ... 57
4.2.1Current State Analysis ... 57
4.2.2Current Situation Simulation ... 65
4.3 Line Balancing Results ... 67
4.3.1Largest Candidate Rule (LCR) ... 68
4.3.2Incremental Utilization Heuristic Method ... 73
4.3.3What If Analysis ... 79
4.4 Concluding Remark... 83
CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 85
5.1 Conclusions... 85
5.2 Recommendations ... 85
GLOSSARY ... 87
REFERENCES ... 88
APPENDIX A – STATION ALLOCATION CURRENT ... 91
APPENDIX B – STATION ALLOCATION LCR ... 93
APPENDIX C – STATION ALLOCATION IUH ... 96
APPENDIX D – STATION ALLOCATION WIA ... 99
Curriculum Vitae ... 101
