DESIGN AND SIMULATION OF CAPACITY PLANNING TO INCREASE PRODUCTIVITY: A CASE STUDY AT PT. XYZ
By
DEVI SURLIYANTI 1-1211-065
BACHELOR’S DEGREE In
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY EduTown BSD City
Tangerang 15339 Indonesia
August 2015
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains neither 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.
Devi Surliyanti Student
Approved by:
Dr. Ir. Yuki Indrayadi, MME Thesis Advisor
Dr. Ir. Prianggada Indra Tanaya, MME Thesis Co-Advisor
Date
Date
Date
ABSTRACT
DESIGN AND SIMULATION OF CAPACITY PLANNING TO INCREASE PRODUCTIVITY: A CASE STUDY AT PT.XYZ
By Devi Surliyanti Yuki Indrayadi, Advisor Prianggada Indra Tanaya, Co-Advisor
SWISS GERMAN UNIVERSITY
PT.XYZ required a plan to increase productivity related to future demand. In this work, three procedures are explored, namely, analysis of current production system, forecasting demand, and design of new production system. Primary and secondary data are required to analyse current production system, also, the work sampling method is used to measure capacity of every machine and equipment. Forecasting demand uses exponential and power trendline forecasting method. The forecasted demand is required to develop new system of production. Simulation software used is AnyLogic as a tool in analysing existing model and developing the alternative model. The result of this research is a proposed model including modifications of machine arrangement, additional equipment that is able to increase the productivity of the system.
Keywords: Capacity Planning, Simulation, AnyLogic, Mining, forecasting method
© Copyright 2015 By Devi Surliyanti All rights reserved
DEDICATION
I dedicate this works to my parents and my sisters (Nita and Cindy) for their support and companions.
ACKNOWLEDGEMENTS
I would like to express great gratitude to God. His blessings and guidance lead me to finish this thesis.
I would like to thank my family for the companion, and unconditional love, especially for my parents to support me, encourage me, and motivate me to finish my education.
I would also to thank my advisor Dr. Ir. Yuki Indrayadi, MME and Dr. Ir. Prianggada Indra Tanaya, MME for helping, guiding and motivating me and for the contribution to the completion of this thesis.
I would like to extend my thanks to all my friends in industrial engineering batch 2011 for all this four past years.
I would like to extend my thanks to Bhagya Rio Ellardo, Floretta Viasasky, Meidisa Joane, Audrey Halim, Joshua Hadi, Edward Dewandana for encouraging me spritually in every condition.
TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER 1 – INTRODUCTION ... 14
Background ... 14
Thesis Description ... 14
Problem Identification ... 15
Research Purpose ... 15
Significance of Study ... 16
Assumptions ... 16
Thesis Organization ... 16
CHAPTER 2 – LITERATURE REVIEW ... 18
Introduction ... 18
Previous Studies ... 18
Implementation of Capacity Planning in Supply Chain Mineral Resources (Fung, et al., 2013) ... 18
Mining Equipment Planning to achieve production target 1750000 WMT Saprolit yearly in Nickel mining Moronopo PT.ANTAM TBK in North Maluku (Ngelow, 2007) ... 19
Decoupled Optimization and Simulation (Case study: PT. Lihir Gold Limited) (Johansson, et al., 2010) ... 19
Integrated Optimization and Simulation (Case Study: PT Kaltim Prima Coal) (Johansson, et al., 2010) ... 20
Designing System Modelling to Reduce Queuing Time for Indonesia
Ferry Customers (Rinjani, 2013) ... 21
Computer Simulation Technology and Demonstration (Schafrik, et al., 2004) 21 Concluding Remarks ... 23
CHAPTER 3 – METHODOLOGY ... 24
Introduction ... 24
Overview of Company ... 24
Company Background ... 24
Machine and Equipment Specification (Shanbao, t.thn.)... 25
Products Overview ... 35
Capacity Planning ... 37
Capacity Definition ... 37
Purpose of Capacity Planning ... 38
Capacity, Load, and Demand (Russel & Taylor, 2011) ... 38
Procedures of Capacity Planning ... 39
Work Sampling Method (Salvendy, 2001) ... 41
Procedures in Demand Forecasting ... 46
Benefits and Shortcomings of Simulation (Banks, et al., 2010) ... 48
Discrete Event Simulation ... 49
Application of Simulation (Banks, et al., 2010) ... 49
Simulation by Any Logic (Banks, et al., 2010) ... 49
Statistical Model (Rinjani, 2013) ... 50
Steps in Simulation ... 51
Methodology ... 58
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 61
Introduction ... 61
Analysis of Current System ... 62
Current Production System ... 62
Flow Process Chart ... 63
Products based on Production ... 65
Output Analysis ... 66
Effective Working Time ... 72
Forecasting Demand ... 73
Conceptual Model ... 79
Simulation ... 80
Assumptions ... 81
Model Translations ... 81
Model Verification ... 89
Model Validation ... 89
Simulation Run Length ... 90
Design of Future System ... 91
2D Simulation of proposed model ... 101
The Impact of mining on environment and decreasing the impact by Reforestation ... 102
Concluding Remarks ... 102
CHAPTER 5 – CONCLUSIONS and recommendations ... 103
Conclusions ... 103
Recommendations ... 103
GLOSSARY ... 105
REFERENCES ... 106
APPENDICES ... 108
APPENDIX A – CONTACT REPORT ... 108
APPENDIX B – WORK SAMPLING DATA ... 110
CURRICULUM VITAE ... 117
