Planning of a make-to-order production process in the printing industry

Songkok Ikat Kepala was one of UKM which produce songkok in Gresik. This UKM Songkok Ikat Kepala was produced by strategy “make to order” and there was no guideline for period production. Problems that occurred were known asdelayed production process at the process of sewing. The aim of this study was (1) to analyze the planning of labor scheduling and (2) to determine the standard of estimation of item production process. The data were analyzed by using period study and gantt diagram techniques. The results of the study showed that there were 2 standards of estimation, those are fast and low standards. Fast standard needed the work estimation in 444 seconds. However, low standard needed the work estimation in 536 seconds. Therefore, this study was expected to be guidance to arrange the schedule by using gantt diagram.

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ANALISA PERBANDINGAN PENJADWALAN PRODUKSI DENGAN METODE CDS (CAMPBELL DUDEK SMITH), EDD (EARLIEST DUE DATE) DAN FCFS (FIRST COME FIRST SERVE) PADA PT. SARI WARNA ASLI UNIT V

Journal of Industrial Engineering and Technology ◽

10.24176/jointtech.v1i2.6499 ◽

2021 ◽

Vol 1 (2) ◽

pp. 46-51

Author(s):

Dwi Ayu Lestari, Vikha Indira Asri

Keyword(s):

Production Process ◽

Production System ◽

Production Scheduling ◽

Job Shop ◽

Allocation Of Resources ◽

Due Date ◽

Scheduling System ◽

Make To Order ◽

First Come First Serve ◽

Scheduling Method

Scheduling is defined as the process of sequencing the manufacture of a product as a whole on several machines. All industries need proper scheduling to manage the allocation of resources so that the production system can run quickly and precisely as of it can produce optimal product. PT. Sari Warna Asli Unit V is one of the companies that implements a make to order production system with the FCFS system. Thus, scheduling the production process at this company is also known as job shop production scheduling. The methods used in this research are the CDS method, the EDD method and the FCFS method. The purpose of this research is to minimize the production time and determine the best method that can be applied to the company. The results of this research showed that the makespan obtained in the company's scheduling system with FCFS rules was 458 minutes, and the results of scheduling using the CDS method obtained a makespan value of 329 minutes, then the best production scheduling method that had the smallest makespan value was the CDS method.

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The effectiveness of single minute exchange of dies for lean changeover process in printing industry

MATEC Web of Conferences ◽

10.1051/matecconf/201815401064 ◽

2018 ◽

Vol 154 ◽

pp. 01064 ◽

Cited By ~ 1

Author(s):

Sri Indrawati ◽

Mentari Endah Pratiwi ◽

Sunaryo ◽

Abdullah ‘Azzam

Keyword(s):

Process Improvement ◽

General Problem ◽

Lean Production ◽

Setup Time ◽

Order System ◽

Printing Industry ◽

Make To Order ◽

Production Wastes ◽

Long Time ◽

Large Product

The changeover time is a factor that greatly affects the lean production implementation in industry with make to order system. Large product variations and unpredictable quantity of orders will trigger some kind of production wastes if changeover time is done in a longer time. One industry with make to order system is printing industry. In general, to produce several types of products such as books takes quite a long time because of long production changeover process. The general problem faced is the delay in book’s production completion. Based on this problem, changeover time reduction is needed to overcome the delay of book’s production completion using single minute exchanges of dies (SMED) method. The SMED method is the method that separates the changeover activity into two, i.e. internal setup and external setup. The research shows that changeover time for printing workstation is 18 minutes 29 seconds, which consists of internal setup activities 14 minutes 37 seconds and external setup 4 minutes 33 seconds. By converting 45% of the internal setup activity into an external setup, then the setup time can be reduced. The initial setup activities performed when machine is stop, now can be done when the machine is running. In addition, a changeover process improvement also done using 5S method in workstation tools area so the internal setup time is reduced 46% becomes 7 minutes 59 seconds. Under these conditions, the printing industry can increase production by 2%.

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An Integrated Production System Model and Project Plan Restricted Pull-Way Production Control Method for Lean Shipbuilding

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.385-386.1852 ◽

2013 ◽

Vol 385-386 ◽

pp. 1852-1859

Author(s):

Ming Di Zong ◽

Hou Fang Sun

Keyword(s):

Production Process ◽

Lean Manufacturing ◽

Production Control ◽

Control Method ◽

Control Area ◽

Integrated System ◽

Middle Level ◽

Receding Horizon ◽

Make To Order ◽

Project Plan

Shipyards are facing challenges when trying to manage their project plan under make to order mode and, at the same time, control their production process in a pull way according to the lean manufacturing principle. A Lean shipbuilding planning and pull-way control integrated system (LSPCIS) model is established, which provides the architecture of realizing the lean principle in planning and production control area for shipbuilding. Then, a Project Plan Restricted Pull-way production control method (PPRP) is introduced where the bottom level is based on pull principle, while under the restriction of receding horizon plan and project plan. The study reveals that even under the make to order production mode of shipbuilding, it is still possible to establish a leanness oriented planning and production Control system, where the receding horizon plan can work as a middle level between the project plan and pull-way production control. The result of a production process simulation is introduced at the end of the paper, to validate the advantage of the PPRP control method comparing with the normal KANBAN control and pure push way of material delivery.

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Usulan Penjadwalan Job Machine Seri Menggunakan Metode Campbell Dudek Smith (CDS) untuk Meminimasi Makespan di UD. Wira Vulkanisir

Jurnal Energi Dan Manufaktur ◽

10.24843/jem.2019.v12.i02.p03 ◽

2019 ◽

Vol 12 (2) ◽

pp. 62

Author(s):

Tengku Nurainun ◽

Wira Oktiandri

Keyword(s):

Production Process ◽

Production System ◽

Customer Demand ◽

Scheduling System ◽

Important Thing ◽

Make To Order ◽

Speed Up ◽

A Company ◽

Actual Method

Dalam perkembangan industri saat ini yang terus maju maka setiap perusahaan dituntut untuk dapat bersaing dan mempunyai strategi yang tepat agar tidak ketinggalan dari perusahaan pesaing yang lainnya. Strategi dari perusahaan itu sendiri bermacam-macam, dapat berupa peningkatan kualitas, ketepatan waktu penyelesaian suatu pekerjaan dan lain sebagainya. UD. Wira Vulkanisir merupakan suatu perusahaan yang bergerak di bidang vulkanisir ban, dengan jenis sistem produksi yang diterapkan yaitu MTO (Make To Order) dimana perusahaan ini sering mengalami keterlambatan dalam pengirim kepada konsumen, yang tentunya berdampak terhadap performa perusahaan itu sendiri. Penjadwalan dengan menggunakan metode CDS pada bulan maret 2019 mengahsilkan urutan job 9-8-7-6-3-4-2-5-1 dengan makespan sebesar 284,49 jam dimana metode ini lebih optimal dibandingkan dengan metode aktual perusahaan dengan selisih makespan sebesar 17,29 jam.Dari hasil penjadwalan menggunakan metode CDS dapat mempercepat proses produksi sebesar 5,6% di bandingkan penjadwalan perusahaan saat ini. Oleh karena ini itu, penajdwalan menggunakan metode CDS dapat di pertimbangkan oleh perusahaan untuk di terapkan di lantai produksi. In an industry scheduling is a very important thing to support the productivity of a company. Therefore, to meet customer demand and satisfaction, a scheduling system that is properly planned, effective and efficient is needed. UD. Wira Vulkanisir is a company engaged in tire retreading, with the type of production system being applied, namely MTO (Make To Order) where the company often experiences delays in the sender to consumers, which of course has an impact on the performance of the company itself. Scheduling using the CDS method in March 2019 produces a sequence of jobs 9-8-7-6-3-4-2-5-1 with makespan of 284.49 hours where this method is more optimal than the actual method of the company with a difference of makespan of 17.29 hours. From the results of scheduling using the CDS method it can speed up the production process by 5.6% compared to the current company scheduling. Because of this, the prediction of using the CDS method can be considered by the company to be applied on the production floor.

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Penggunaan Algoritma Simulated Annealing dalam Penyelesaian Keterlambatan Order di PT. HTS

Talenta Conference Series Energy and Engineering (EE) ◽

10.32734/ee.v2i2.444 ◽

2019 ◽

Vol 2 (2) ◽

Author(s):

Harry Tusuccess ◽

Rosnani Ginting

Keyword(s):

Simulated Annealing ◽

Production Process ◽

Simulated Annealing Algorithm ◽

Flow Shop ◽

Order System ◽

Production Flow ◽

Make To Order ◽

Plant Uses ◽

Sorting Process ◽

Clear Plastic

PT. HTS adalah salah satu perusahaan yang bergerak di industri pembuatan plastik dengan 3 jenis produk yaitu joly, cangkir plastik bening, dan cangkir plastik printing. Pemenuhan produksi di pabrik ini menggunakan sistem make to order, aturan First Come First Served dan aliran produksi berdasarkan flow shop. Proses produksi sering mengalami penumpukan job dan keterlambatan order. Penelitian dilaksanakan pada unit produksi cangkir plastik bening di enam work center di lantai produksi PT. HTS. Penelitian dilaksanakan pada proses produksi bulan Juli 2013 pada tipe produk AAA, BBB, CCC, DDD, EEE, dan FFF. Kriteria penjadwalan yang digunakan hanya berupa pengurutan job dengan dasar penilaian fungsi makespan.. Jumlahnya mesin terbatas mengakibatkan banyak pekerjaan (job) yang delay, maka mesin yang dijadwalkan dengan baik diharapkan akan dapat mengurangi delay pada pekerjaan (job). Penjadwalan mesin dilakukan dengan menggunakan metode Simulated Annealing dengan proses pengurutan pekerjaan dimana proses tidak ada yang lebih awal tanpa menghambat (delay) operasi lainnya. Penjadwalan kondisi aktual menghasilkan waktu penyelesaian keseluruhan produk sebesar 24480,71 menit = 408,01 jam = 17 hari. Sedangkan penjadwalan menggunakan algoritma Simulated Annealing menghasilkan waktu penyelesaian keseluruhan produk sebesar 20091,71 menit = 334,99 jam = 13,95 hari = 14 hari . Penjadwalan yang dipilih adalah Simulated Annealing karena memiliki waktu penyelesaian keseluruhan produk yang paling minimum dan pengurangan makespan sebesar 4381 menit. Dengan urutan job pengerjaan yaitu CCC, AAA. DDD, FFF, BBB, dan EEE. PT. HTS is a company engaged in the manufacture of plastic with 3 types of products, namely joly, clear plastic cups, and plastic printing cups. Fulfillment of production at this plant uses the make to order system, First Come First Served rules and flow shop based production flow. The production process often experiences job buildup and late orders. The research was carried out in a clear plastic cup production unit in six work centers on the production floor of PT. HTS. The research was carried out in the production process in July 2013 on AAA, BBB, CCC, DDD, EEE, and FFF products. The scheduling criteria used are only in the form of sorting jobs on the basis of an assessment of the makespan function. The limited number of machines results in many delays, then a well-scheduled machine is expected to reduce job delay Machine scheduling is done by using the Simulated Annealing method with the sorting process of work where there is no earlier process without delaying other operations. Scheduling actual conditions results in the completion of the entire product amounting to 24480.71 minutes = 408.01 hours = 17 days. While scheduling using the Simulated Annealing algorithm results in the completion of the entire product by 20091.71 minutes = 334.99 hours = 13.95 days = 14 days. The chosen schedule is Simulated Annealing because it has the minimum overall product completion time and a reduction of makespan of 4381 minutes. With the order of work that is CCC, AAA. DDD, FFF, BBB and EEE.

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Perancangan alat bantu untuk memperbaiki proses perencanaan produksi pada PT X

Jurnal Manajemen Maranatha ◽

10.28932/jmm.v19i1.1003 ◽

2019 ◽

Vol 19 (1) ◽

pp. 21-34

Author(s):

Hans Gerald Regawa

Keyword(s):

Production Process ◽

Production Planning ◽

Raw Materials ◽

Raw Material ◽

Planning System ◽

Order System ◽

System A ◽

Work In Process ◽

Make To Order ◽

A Company

Production planning is part of the operational management that is important in a company. By managing production planning properly, the production process in a company will be able to run better. PT X is a company that produces vehicle spareparts for private cars. The company runs make to order system to fulfill the production procss. In the make to order system, a new product will begin to be produced by the company if there is an order from the customer. In this system, a company has inventory i.e. raw material and work in process. The problem are PT X have lack of raw materials and the absence of lead time given by the company to customers about when a product will be sent. To overcome this problem, improvements are made to the existing production planning system. Improvements begin by changing the way raw materials are purchased. This is done by treating the system with order point. With this system, company will never experience a shortage of raw materials because when raw material below order point, company must immediately order new raw materials. Thus the production process will not be disturbed and can run smoothly. In determining when a product will be completed and sent to customers, a production planning system with DSS tools (decision support system) is made using Microsoft Excel tools. By using DSS, the system will automatically display when a product will be finished and when it can be sent to the customer, when to buy raw materials, and how much production order is. Accordingly, the company can provide certainty of information to customers when the products have been produced and shipped.

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Menurunkan Problem Reject Pinhole di Proses dengan Konsep DMAIC di PT. XYZ, Purwakarta

JIE Scientific Journal on Research and Application of Industrial System ◽

10.33021/jie.v3i2.527 ◽

2019 ◽

Vol 3 (2) ◽

pp. 119

Author(s):

Hikmat Mulyana M ◽

Andira Andira ◽

Nurhayati Surbakti

Keyword(s):

Production Process ◽

Current Density ◽

Six Sigma ◽

Flexible Manufacturing ◽

Manufacturing Industries ◽

Printing Industry ◽

Cleaning Process ◽

Customer Complaints ◽

Analysis Process ◽

Dmaic Method

PT XYZ is one of the flexible manufacturing industries. In terms of overcoming competition in the printing industry, PT XYZ built the Rotogravure company in 2011. The subsidiary is engaged in manufacturing Cylinder Rotogravure which supplies PT XYZ units. From a few years back since the establishment of this company, the target that should have been reached in amount of 5760 Cylinder / year. This target hasnot been achieved. This occurs because there is a problem in the production process reaching ± 49.4% and continues to appear which results in a disrupted delivery schedule, many customer complaints due to the low quality goods being shipped.The method used for this improvement process is the system or concept of Six Sigma namely DMAIC. From the DMAIC method, the tools used for the analysis process are the Pareto, Fishbone, 5W1H and Data Sheet diagrams. These tools are core tools that are focused on finding problems that often occur at PT XYZ. From the results of this improvement, a design is got to make the cleaning process aids, there were changes in parameters in the production process by reducing the current density and temperature in the Copper machine with a temperature of 30OC and current density of 20 A / dm2. The research and improvements that have been made are 94.45% with a total pinhole wastage of 1 cylinder unit.

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