Sangadji, Rhyzalaita Adhi (2026) Pengembangan Model Kapasitas Produksi Adaptif Berbasis Theory Of Constrains dan Workforce Agility untuk Mengatasi Dynamic Bottleneck Pada Lingkungan Manufaktur Make-To-Order. Masters thesis, Institut Teknlogi Sepuluh Nopember.
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Abstract
Industri manufaktur make-to-order (MTO) padat karya menghadapi lumpy demand yang memicu dynamic bottleneck dan ketidakstabilan kapasitas. Penelitian ini mengembangkan model kapasitas produksi adaptif yang mengintegrasikan Theory of Constraints (TOC) sebagai alat diagnosis, workforce agility sebagai mekanisme adaptasi kapasitas, dan Discrete Event Simulation (DES) sebagai alat validasi, pada lini produksi water meter dengan 27 operator dan lima stasiun kerja. Diagnosis TOC mengidentifikasi struktur kendala berlapis: administrative constraint pada pengelompokan batch, operational near-constraint pada stasiun Welding Cover (utilisasi 61,15%), dan latent dynamic bottleneck pada titik sinkronisasi jalur paralel. Model adaptif yang dirancang terdiri atas Adaptive Skill Matrix, Adaptive Rotation Decision Algorithm (ARDA) dengan lima aturan rotasi berbasis ambang utilisasi dan antrian, serta process resequencing pada stasiun Laser Marking, divalidasi melalui 30 replikasi simulasi Arena. Hasil menunjukkan penurunan utilisasi Welding Cover sebesar 49,94% (p < 0,001; Cohen’s d = −9,57), waiting time stasiun tersebut 93,07%, dan waiting time rework loop 93,16% — seluruhnya signifikan. Throughput bertahan setara (p = 0,652), hasil yang justru memvalidasi diagnosis bahwa kendala throughput bersifat administratif dan di luar jangkauan realokasi tenaga kerja. Analisis sensitivitas menunjukkan amplop operasi melebar 3,6 kali lipat, sementara robustness testing mengungkap single point of failure pada konfigurasi eksisting yang tereliminasi oleh model adaptif. Kontribusi penelitian berupa mekanisme keputusan eksplisit yang menjembatani diagnosis kendala dengan realokasi tenaga kerja, tipologi kendala berlapis untuk MTO padat karya, serta penetapan batas domain keberlakuan workforce agility secara kuantitatif.
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Labor-intensive make-to-order (MTO) manufacturing systems face lumpy demand, which triggers dynamic bottlenecks and destabilizes capacity. This study develops an adaptive production capacity model integrating the Theory of Constraints (TOC) as a diagnostic instrument, workforce agility as a capacity adaptation mechanism, and Discrete Event Simulation (DES) as a validation tool, applied to a water meter production line with 27 operators across five workstations. The TOC diagnosis identifies a layered constraint structure: an administrative constraint in the batch grouping mechanism, an operational near-constraint at Welding Cover (61.15% utilization), and a latent dynamic bottleneck at the parallelline synchronization point. The adaptive model comprises an Adaptive Skill Matrix, an Adaptive Rotation Decision Algorithm with five rotation rules triggered by utilization and queue thresholds, and process resequencing of the Laser Marking station, validated through 30 Arena simulation replications. Results show a 49.94% reduction in Welding Cover utilization (p < 0.001; Cohen’s d = −9.57), a 93.07% reduction in its waiting time, and a 93.16% reduction in rework loop waiting time — all statistically significant. Throughput remained equivalent (p = 0.652), validating the diagnosis that the throughput constraint is administrative and beyond the reach of workforce reallocation. Sensitivity analysis shows the operating envelope expands 3.6-fold, while robustness testing reveals a single point of failure in the existing configuration that the adaptive model eliminates. This study contributes an explicit decision mechanism bridging constraint diagnosis and workforce reallocation, a layered constraint typology for labor-intensive MTO contexts, and a quantitative delimitation of the applicability domain of workforce agility.
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