SECTION OF AUTOMOTIVE MANUFACTURING COMPANY
By
Elbert Charistheo 11607015
BACHELOR’S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
June 2020
Revision after Thesis Defense on July 8, 2020
Elbert Charistheo 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.
Elbert Charistheo
_____________________________________________
Student Date
Approved by:
Dr. Tanika D. Sofianti, S.T., M.T.
_____________________________________________
Thesis Advisor Date
Dr. Eng. Aditya T. Pratama, S.Si., M.T.
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc.
_____________________________________________
Dean Date
Elbert Charistheo ABSTRACT
MATERIAL HANDLING SYSTEM IMPROVEMENT IN INJECTION SECTION OF AUTOMOTIVE MANUFACTURING COMPANY
By
Elbert Charistheo
Dr. Tanika D. Sofianti, S.T., M.T., Advisor Dr. Eng. Aditya T. Pratama, S.Si., M.T., Co-Advisor
SWISS GERMAN UNIVERSITY
Material handling is an important aspect in the industry. Material handling supports all the supply for production which is why it plays a crucial role in the production line.
Manual material handling uses workers to keep the supply of parts from storage to the assembly line. This research study is based on PT. Suzuki Indomobil Motor Injection Section material handling problem. The material handling system is complex and not efficient. There are too many unnecessary movements for instance it took too many steps to supply the parts. This movement is seen as not efficient and categorized as waste in Lean Manufacturing. Therefore, the main purpose of this thesis is to improve company productivity in the material handling system. The data is gathered by observation the whole process in the injection section. DMAIC method is used as the main method to analyze the problem and to develop the solution. The Six Phases of The Generic Product Development Process is used to further develop the design of the supporting tool. The improvement will design the supporting tools to be able to fulfill the requirement from the company which is low cost and able to improve the current system. The solution will reduce waste of movement in material handling and thus improve the productivity in the section by 19.6%.
Keywords: Material Handling, Supporting Tools, Lean Manufacturing, DMAIC, Six Phases of The Generic Product Development Process.
Elbert Charistheo
© Copyright 2020 by Elbert Charistheo
All rights reserved
Elbert Charistheo DEDICATION
I dedicate this works to my family
and the lecturers in Industrial Engineering Department of Swiss German University and also, to my friends who keep supporting me to finish the thesis.
Elbert Charistheo ACKNOWLEDGEMENTS
I would like to thank Mr. Yudo Nendito and Mr. Deniro Adriansyah for the opportunity to have a thesis internship and to Mr. Syah Hardi as the supervisor in the company for the guidance to finish the thesis.
Elbert Charistheo 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 ... 13
1.1 Background ... 13
1.2 Research Problems ... 16
1.3 Objectives ... 16
1.4 Research Scope and Limitation ... 16
1.5 Significant of Study ... 17
1.6 Thesis Structure ... 17
CHAPTER 2 - LITERATURE REVIEW ... 19
2.1 Material Handling ... 19
2.2 Facility Design and Layout ... 20
2.3 Inventory Management System ... 21
2.4 Lean Manufacturing in Logistic ... 22
2.5 Discrete Event Simulation ... 24
2.6 Six Sigma and DMAIC Method ... 25
2.7 Six Phases of The Generic Product Development Process ... 26
CHAPTER 3 – RESEARCH METHODOLOGY ... 29
3.1 Problem Identification ... 30
Elbert Charistheo
3.3 Data Acquisition by Observation ... 30
3.4 Data Analysis (Motion Study and Spaghetti Diagram) ... 30
3.5 Develop New Procedure and Material Handling Tools... 31
3.6 Standardization by Developing Work Instruction ... 32
3.7 Audit System ... 32
CHAPTER 4 – DESIGN AND DEVELOPMENT ... 33
4.1 Problem Identification ... 33
4.2 Data Gathered by Observation ... 35
4.3 Current Condition Analysis ... 39
4.3.1 Bumper and Jig Rack ... 39
4.3.2 Manual Process of Carrying Bumper from and to Painting Area ... 43
4.4 Develop solution ... 51
4.4.1 Choosing the Idea ... 51
4.4.2 Developing Solution 1 ... 59
4.4.3 Developing Solution 2 ... 66
4.5 Standardize and sustain ... 74
4.5.1 Develop Work Instruction Solution 1 ... 74
4.5.2 Develop Work Instruction Solution 2 ... 75
CHAPTER 5 – SIMULATION ... 77
5.1 Implementation ... 77
5.1.1 Simulation of Current System ... 77
5.1.2 Simulation of Solution 1 System ... 79
5.1.3 Simulation of Solution 2 System ... 82
5.1.4 Simulation Analysis ... 84
5.2 Work Instruction Validation ... 85
5.3 Cost Estimation Analysis ... 85
CHAPTER 6 – CONCLUSIONS AND RECOMENDATIONS ... 87
Elbert Charistheo
6.2 Recommendations ... 89
REFERENCES ... 90
APPENDIES ... 92
CURRICULUM VITAE ... 100
Elbert Charistheo LIST OF FIGURES
Figures Page
Figure 1.1 Current Injection Layout ... 15
Figure 2.1 Literature Review ... 19
Figure 2.2 DMAIC Method ... 25
Figure 2.3 Six Phases of The Generic Product Development Process ... 26
Figure 3.1 Research Methodology ... 29
Figure 3.2 Spaghetti Diagram (Current Activity) ... 31
Figure 4.1 5 Why Analysis ... 34
Figure 4.2 Current Layout ... 35
Figure 4.3 Current Layout ... 36
Figure 4.4 Process of Moving Bumper from Rack to Painting Area ... 38
Figure 4.5 Painting Area Conveyor ... 39
Figure 4.6 Bumper Rack Naming ... 40
Figure 4.7 Bumper Rack ... 41
Figure 4.8 Current Bumper Rack Side View ... 42
Figure 4.9 Current Bumper Rack 3D View ... 42
Figure 4.10 Bumper Jig ... 43
Figure 4.11 Bumper Rack with Bumper and Jig ... 43
Figure 4.12 Operator Walking between Racks to Fix Stuck Bumpers ... 44
Figure 4.13 Operator Walking Towards Bumper Rack ... 46
Figure 4.14 Process of Setting Up Bumper in The Painting Area ... 48
Figure 4.15 Worker Bumper Loading in Painting Area... 49
Figure 4.16 Spaghetti Diagram Analysis ... 50
Figure 4.17 Conveyor Illustration ... 53
Figure 4.18 Conveyor Idea Layout ... 53
Figure 4.19 Redesign Layout Draft Idea ... 55
Figure 4.20 Karakuri Rack Illustration ... 56
Elbert Charistheo
Figure 4.22 Cart Solution 1 (Left) and Cart with Bumper Illustration (Right) ... 64
Figure 4.23 Proposed Solution 1 Layout ... 66
Figure 4.24 Proposed Solution 2 Layout ... 68
Figure 4.25 Cart Solution 2 (Left) and Cart with Bumper Illustration (Right) ... 70
Figure 4.26 Lifter Design Illustration ... 71
Figure 4.27 Bumper Lifter in Bumper Rack Illustration ... 72
Figure 5.1 Current System Simulation ... 78
Figure 5.2 Current Simulation Result ... 79
Figure 5.3 Solution 1 Simulation ... 80
Figure 5.4 Solution 1 Simulation Result ... 81
Figure 5.5 Solution 2 Simulation ... 82
Figure 5.6 Solution 2 Simulation Result ... 83
Elbert Charistheo LIST OF TABLES
Tables Page
Table 4.1 Observation Data ... 37
Table 4.2 Number of Steps Table ... 38
Table 4.3 Motion Study Table ... 45
Table 4.4 Motion Study Table for Rack A ... 45
Table 4.5 Number of Steps and Time Table ... 61
Table 4.6 Current Activity Gantt Chart ... 65
Table 4.7 Solution 1 Activity Gantt Chart ... 65
Table 4.8 Solution 2 Activity Gantt Chart ... 73
Table 5.1 Simulation Result Summary ... 84
Table 5.2 Estimated Pricelist ... 85
Table 5.3 Solution 1 Pricelist ... 86
Table 5.4 Solution 2 Pricelist ... 86
Table 6.1 Result Summary ... 88
