Improvement Of Fully Automated Manufacturing Cells By Labor Utilization And Overall Equipment Effectiveness: A Discrete Event Simulation Study

Arunajati, Arnoldus Arkkawimba (2022) Improvement Of Fully Automated Manufacturing Cells By Labor Utilization And Overall Equipment Effectiveness: A Discrete Event Simulation Study. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. XYZ is a company that take part in the fast-moving consumer goods industry in Indonesia. PT. XYZ have a factory where they manufacture their own products. PT. XYZ’s factory uses group technology philosophy based on packaging technology and implements cellular manufacturing in their production area. PT. XYZ’s factory operates 4 sachet manufacturing cells. These sachet manufacturing cells are operated by 10 operators. By recent internal studies, this labor assignment policy is considered inefficient and results in the average of 45% labor utilization. However, changes in labor assignment policy and labor staffing level may impact manufacturing cells’ overall equipment effectiveness (OEE) negatively, as manufacturing cells are dual-constrained system where the performance of the cell is the result of combination of labor availability and machine availability. Discrete event simulation study is to help PT. XYZ’s factory improve its condition. There are four control variables that is going to be simulated. They are reel length, case erector magazine capacity, operator break time, and labor staffing level. Each individual values of control variables are tested and the one that yields the best results are selected. The best control variables value then combined with each other and simulated. All the simulation result is compared with each other, and the best scenario is proposed to PT. XYZ to be implemented. The best scenario is reducing operator break time to 50 and 90 minutes, reducing the number of operators from 10 to 7, and increasing reel length from 1000 meters to 1500 meters. This scenario yields better OEE at 77.3% compared to the existing condition of 75%. It also yields higher average labor utilization at 51.18% compared to the existing condition of 38.2%. This improvement scenario also reduces operating cost because there are less operators, and it gives more balanced workload distribution among the workers.
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PT. XYZ adalah sebuah perusahaan yang bergerak di bidang fast moving consumer goods. PT. XYZ memiliki pabrik yang dikelola sendiri, dimana mereka memproduksi produk - produk mereka. Pabrik PT. XYZ menggunakan prinsip group technology dan mengimplementasikan konsep cellular manufacturing. Pabrik tersebut mengoperasikan empat sel produksi sachet. Sel produksi sachet ini dioperasikan oleh 10 orang operator. Dari hasil studi terbaru, jumlah pekerja yang sekarang dirasa tidak efisien dan menghasilkan rata - rata 45% tingkat utilisasi tenaga kerja atau labor utilization. Namun, perubahan pada jumlah dan penugasan operator bisa berakibat buruk pada overall equipment effectiveness (OEE) dari sel manufaktur, karena sell manufaktur adalah dual-constrained system dimana performa dari sebuah sel adalah kombinasi dari ketersediaan tenaga kerja dan ketersediaan mesin. Studi simulasi diskrit bertujuan untuk membantu PT. XYZ dalam memperbaiki kondisi pabriknya. Ada empat variable control yang akan disimulasikan. Yaitu panjang reel, kapasitas magasin case erector, waktu istirahat operator, dan jumlah serta penugasan operator. Nilai - nilai terbaik dari setiap variable akan dikombinasikan satu sama lain, dan skenario terbaik akan diajukan sebagai skenario perbaikan kepada PT. XYZ. Skenario terbaik didapatkan setelah mengurangi istirahat operator menjadi 50 dan 90 menit, mengurangi jumlah operator dari 10 menjadi 7, dan menambah panjang reel dari 1000 meter menjadi 1500 meter. Skenario perbaikan ini meningkatkan OEE dari 75% menjadi 77.3%. Skenario ini juga meningkatkan utilisasi tenaga kerja dari 38.2% menjadi 51.18%. Perbaikan ini juga mengurangi biaya operasional karena jumlah operator dikurangi, lalu juga memberikan penyebaran beban kerja yang lebih seimbang diantara operator.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	cellular manufacturing, simulasi diskrit, group technology, utilisasi tenaga kerja, overall equipment effectiveness, cellular manufacturing, discrete event simulation, group technology, labor utilization, overall equipment effectiveness
Subjects:	T Technology > TS Manufactures > TS176 Manufacturing engineering. Process engineering (Including manufacturing planning, production planning)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Mr. Marsudiyana -
Date Deposited:	10 Feb 2026 08:59
Last Modified:	10 Feb 2026 08:59
URI:	http://repository.its.ac.id/id/eprint/132326

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