Pemodelan Dan Analisis Konfigurasi Final Test Line Industri Perakitan Otomotif Menggunakan Discrete-Event Simulation

Dewanto, Moh. Ardi Chandra (2026) Pemodelan Dan Analisis Konfigurasi Final Test Line Industri Perakitan Otomotif Menggunakan Discrete-Event Simulation. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Final Test (FT) Line merupakan quality gate terakhir dalam lini perakitan otomotif yang memproses tujuh varian kendaraan melalui 46 jenis pekerjaan pada 28 pos kerja dalam konfigurasi dua lini paralel zona CT180. Beberapa pos menunjukkan utilisasi tinggi dengan indikasi bottleneck laten yang tidak teridentifikasi secara visual, sementara manajemen mempertimbangkan konsolidasi dua lini tanpa basis kuantitatif. Penelitian ini membangun model Discrete-Event Simulation (DES) menggunakan Arena 16.20. Data cycle time dikumpulkan melalui time study (39 dataset, 780 observasi) dan diuji menggunakan uji keseragaman, kecukupan N′, dan independensi Runs Test di Minitab 21; distribution fitting menghasilkan empat famili distribusi dengan interarrival NORM(90,2; 2) detik. Validasi model menggunakan uji-t Welch menghasilkan percentage error 1,10% dan p-value 0,118 sehingga model dinyatakan valid. Analisis baseline mengidentifikasi Pos 14 sebagai bottleneck primer (utilisasi 89,35%; waktu tunggu 420,37 detik; kontribusi 44,9% dari total waiting time entitas), Pos 15 sebagai bottleneck sekunder, dan Pos 27 sebagai bottleneck laten (rasio beban 94,8%). Tiga skenario dievaluasi dengan 30 replikasi dan α* = 0,017 (Bonferroni). Skenario 1 (konsolidasi satu lini) menurunkan throughput 43,84% dan membentuk dua bottleneck baru. Skenario 2 (Production Levelling, siklus 37 unit: 13 H + 5 M + 19 L) meningkatkan throughput 2,70% (p = 7,20 × 10⁻⁶) dan menurunkan waktu tunggu Pos 14 sebesar 65,72% tanpa tambahan kapasitas. Skenario 3 (rebalancing UB Rear ke Pos 16) menurunkan waktu tunggu Pos 14 sebesar 26,99% namun tidak signifikan secara statistik. Skenario 2 Production Levelling ditetapkan sebagai rekomendasi utama.
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The Final Test (FT) Line is the last quality gate in an automotive assembly plant, processing seven vehicle variants through 46 job types across 28 workstations in a dual-parallel CT180 configuration. Certain stations exhibited high utilization and latent bottlenecks undetectable on the shop floor, while management considered single-line consolidation without adequate quantitative basis. This research builds a Discrete-Event Simulation (DES) model using Arena 16.20. Cycle time data were collected via time study (39 datasets, 780 observations) and validated through uniformity, adequacy (N′), and independence (Runs Test) tests in Minitab 21; distribution fitting yielded four families with interarrival NORM(90.2; 2) seconds. Model validation using a Welch t-test yielded a percentage error of 1.10% and p-value of 0.118 (H0 not rejected), declaring the model valid. Baseline analysis identified Station 14 as the primary bottleneck (89.35% utilization; mean waiting time 420.37 seconds; contributing 44.9% of total entity waiting time), Station 15 as the secondary bottleneck, and Station 27 as a latent bottleneck (load ratio 94.8%). Three scenarios were evaluated with 30 replications and α* = 0.017 (Bonferroni). Scenario 1 (single-line consolidation) reduced throughput by 43.84% and created two new bottlenecks. Scenario 2 (Production Levelling: 37-unit cycle, 13 H + 5 M + 19 L) increased throughput by 2.70% (p = 7.20 × 10⁻⁶) and reduced Station 14 waiting time by 65.72% without additional capacity. Scenario 3 (rebalancing UB Rear to Station 16) reduced Station 14 waiting time by 26.99% but was not statistically significant (p = 0.080). Scenario 2 Production Levelling is recommended as the primary intervention.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Analisis Bottleneck, Arena, Discrete-Event Simulation, Final Test Line, Production Levelling, Bottleneck Analysis, Arena, Discrete-Event Simulation, Final Test Line, Production Levelling
Subjects:	Q Science Q Science > Q Science (General) Q Science > QA Mathematics
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Moh. Ardi Chandra Dewanto
Date Deposited:	31 Jul 2026 08:35
Last Modified:	31 Jul 2026 08:35
URI:	http://repository.its.ac.id/id/eprint/140765

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