SIMULASI PERBAIKAN PROSES ASSEMBLY PADA LINI PRODUKSI DENGAN PENDEKATAN TOYOTA PRODUCTION SYSTEM MENGGUNAKAN PROMODEL DI PERUSAHAAN MANUFAKTUR SUBSEKTOR OTOMOTIF

, NURDIANTO (2022) SIMULASI PERBAIKAN PROSES ASSEMBLY PADA LINI PRODUKSI DENGAN PENDEKATAN TOYOTA PRODUCTION SYSTEM MENGGUNAKAN PROMODEL DI PERUSAHAAN MANUFAKTUR SUBSEKTOR OTOMOTIF. S1 thesis, Universitas Mercu Buana Bekasi.

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Abstract

ABSTRAK Perkembangan industri otomotif saat ini sedang mengalami hambatan, terlebih dengan kondisi pandemi Covid-19, perusahaan sub sector otomotif mempunyai permasalahan yang cukup serius, yakni cycle time yang melebihi takt time yang telah ditentukan oleh perusahaan juga terdapat perbedaan cycle time yang terlalu senjang antar stasiun yang menyebabkan terjadinya bottle neck proses sehingga sering memberlakukan kerja lembur 4 jam/shift yang melebihi kebijakan manajemen yaitu 2 jam/shift. Dari masalah tersebut peneliti menganalisa dengan pendekatan Toyota Production System dengan dibantu simulasi promodel, dari aktifitas tersebut dievalusai performance line dari sebelumnya efisiensi line sebesar 87.72% Balance Delay 12.28% dan Smoothing Index 10.00 membaik menjadi efisiensi line sebesar 91.03% Balance Delay 8.97% dan Smoothing Index 5.00 tetapi masih terdapat bottle neck, berikutnya dilakukan perbaikan menggunakan line balancing dengan metode Helgeson birnie hasil nilai efisiensi line menjadi 98.61% Balance Delay 1.39% dan Smoothing Index 1.00. Terakhir adalah simulasi hasil perbaikan menggunakan software Promodel. Berdasarkan simulasi Promodel dengan runtime 890 menit, diketahui total exits entitas window regulator finish goods sebanyak 2173 pcs. Kata Kunci: Toyota Production System (TPS), Line Balancing, Simulasi Promodel. ABSTRACT The development of the automotive industry is currently experiencing obstacles, especially with the conditions of the Covid-19 pandemic, the automotive subsector companies have quite serious problems, namely cycle times that exceed the takt time determined by the company, there is also a cycle time difference that is too sparse between stations. causing bottle neck processes so that they often apply overtime work of 4 hours/shift which exceeds the management policy of 2 hours/shift. From this problem, the researcher analyzed the Toyota Production System approach with the help of promodel simulation, from these activities evaluated line performance from the previous line efficiency of 87.72% Balance Delay 12.28% and Smoothing Index 10.00 improved to line efficiency of 91.03% Balance Delay 8.97% and Smoothing Index 5.00 but there is still a bottle neck, then improvements are made using line balancing with the Helgeson Birnie method, the results of the line efficiency are 98.61% Balance Delay 1.39% and Smoothing Index 1.00. The last is the simulation of the repair results using the Promodel software. Based on the Promodel simulation with a runtime of 890 minutes, it is known that the total exits of the window regulator finish goods entity is 2173 pcs. Keywords: Toyota Production System (TPS), Line Balancing, Promodel Simulation

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