Jurnal Sistem Teknik Industri

Lean Approach to Minimize Waste in Biscuit Production Process Using Value Stream Mapping Method at PT. XYZ

Dinda Agustina Lubis, Sugiharto Pujangkoro, Juliza Hidayati — Mon, 29 Jul 2024 00:00:00 +0700

PT XYZ is one of the companies in the snack food industry that focuses on processing biscuits. There is still waste in the production process, such as waiting and transportation, which adds time to the production process and makes it longer. To reduce waste and improve business efficiency, this research uses lean methodology and value stream mapping to ensure the biscuit processing production process runs smoothly. The results of the research that has been done, there is a decrease in non-value-added time by 13.27 minutes from 22.77 minutes, a total lead time of 68.32 minutes from 77.82 minutes, and process cycle efficiency increased by 75.29% from 66.10%. This shows that implementing lean methods using value stream mapping can improve the company's efficiency and productivity.

Integration of Design for Manufacture and Assembly with Product Design in Product Design Improvement: A Systematic Literature Review

Shishilya Yazid, Rosnani Ginting, Nismah Panjaitan — Mon, 29 Jul 2024 00:00:00 +0700

This paper aims to investigate and analyze some previous literature relevant to the Design for Manufacture and Assembly and Design for Safety methods in international journals. An extensive review and analysis of the body of literature was conducted to discuss the findings in a few chosen papers pertaining to the application of both methods, using a survey based on descriptive and qualitative surveys published in international journals with publication period limitations from 2011 to 2023 published in proceedings and electronic journals in English. So far, there has never been any research or literature review that discusses the Integration of Design for Manufacture and Assembly with Design for Safety.

Literature Review of Concurrent Engineering in Kansei Engineering and Ergonomic

Alvin Setiawan, Rosnani Ginting, Aulia Ishak — Mon, 29 Jul 2024 00:00:00 +0700

This research aims to conduct a literature review on the application of the integration of Kansei engineering, ergonomics, and concurrent engineering methods in the context of product design. A systematic study of 8 scholarly journals related to the topic in the last decade indicates that combining these three methods has a positive impact on product performance and the efficiency of the development process. In conclusion, a multidisciplinary approach is highly recommended to produce innovative and highly competitive products through a faster and cost-effective process.

Integration of Value Engineering for Design for Assembly in Product Design: A Comprehensive of Literature Review

Adrian Hartanto, Rosnani Ginting, Aulia Ishak — Mon, 29 Jul 2024 00:00:00 +0700

This study explains the benefits obtained from the integration of Design for Assembly (DFA) and Value Engineering (VE) methods in the product design process. DFA is proven to provide benefits such as product simplification, reduced assembly costs, and improved quality by creating product structures that are simpler and easier to install. While VE adds value by taking into account the replacement of expensive or difficult-to-assemble components, speeding up overall assembly time. Although specific research on the integration of these two methods may be limited, studies show that the combination of DFA and VE produces design alternatives that consider various aspects of the product life cycle. The result is reduced costs, faster development times, and a reduced need for rework. The concepts and benefits of integrative DFA and VE approach can be an effective strategy for enhancing assembly efficiency and reducing production costs in product design.

Life Cycle Analysis Study of Plastic Flower Pot Products

Aulia Ishak, Khawarita Siregar, SS Sarjana — Mon, 29 Jul 2024 00:00:00 +0700

Some flower pots are made of plastic materials. Plastic waste is a global environmental issue with varying quantities and types in different countries. One source of plastic pollution is low-durability plastic pots, commonly used for seeding in agriculture, horticulture, and forestry. Waste from these plastic pots is difficult to decompose by soil microbes, thus posing an environmental contamination risk. Life Cycle Analysis (LCA), also known as life cycle assessment, is a method to measure the environmental impacts of products, such as biofuels. In LCA, researchers prepare an inventory of the resources used (e.g., fossil fuels and raw materials) and substances produced (e.g., greenhouse gases, solid waste, and other pollutants) throughout the full life cycle of production, transportation, and use of the product in question. From this inventory, researchers conduct impact assessments that estimate the final effects on human health, ecosystem function, and depletion of natural resources. This study aims to assess the life cycle analysis of plastic flower pot products from their initial material stage to their disposal as waste, in order to gain insights into the potential for minimizing their environmental impact. The results of research where the production of 600 ml plastic flower pot bottles required 28 grams of plastic resin per bottle, as well as energy for the production and transportation processes. Plastic packaging production produces defective products.

Implementation of Long Short-Term Memory Network for Predicting The Cocoa Crop Yield

Anastasia Lidya Maukar, Laesa Qotrun Nada Arrosyadi — Mon, 29 Jul 2024 00:00:00 +0700

Forecasting models with high accuracy become more important during uncertain conditions, such as climate change, that could have a high effect. The forecast model's accuracy in predicting cocoa crop yield must be high to determine decision-making in management. Seven different potential predictor variables have been analyzed in this research to see the influence of cocoa crop yield. Using a scatter plot diagram, six of seven variables, relative humidity, maximum temperature, minimum temperature, evapotranspiration, rainfall, and soil moisture, are proven to influence cocoa crop yield. Then, those datasets are divided into training and validation sets using multiple linear regression analysis and a Long Short-Term Memory (LSTM) network. The output model of those methods is assessed using two metrics: coefficient of determination and Root Means Square Error (RMSE). From those model performance metrics, LSTM outperformed multiple linear regression analysis. LSTM has an R-square of 98% and an RMSE of 0.3 while multiple linear regression just reached 82% of the R-square and 2.57 of the RMSE. The LSTM model has been proven to be valid.

Implementing Human-Centric Design in Developing a Multifunctional Chair and Storage Solution for Children

Mon, 29 Jul 2024 00:00:00 +0700

This research applies Human-Centric Design (HCD) principles to develop a multifunctional storage solution integrated with a chair, specifically designed for children. By considering the needs and preferences of both parents and young users, we combine ergonomic design elements with practical storage functionality. The resulting product not only organizes children’s belongings for parents but also provides an enjoyable experience for kids. Our study contributes to a deeper understanding of how HCD can effectively create functional and appealing products for parents and child users.

Optimizing Raw Material Inventory Control for Aluminum Wardrobes Using the Material Requirements Planning (MRP) Method: A Case Study on Amal Jaya SME

Mon, 29 Jul 2024 00:00:00 +0700

This study aims to analyze the implementation of Material Requirement Planning (MRP) method in controlling raw material inventory for aluminum wardrobe production in Amal Jaya SME. The inability to accurately predict the average number of customer orders each month indicates unfulfilled consumer demand. Therefore, effective raw material control becomes crucial to ensure availability in accordance with demand. The objectives of this research are to evaluate the management of raw materials using the MRP method and identify its impact on cost efficiency of raw materials in the production process. Additionally, this study aims to optimize raw material inventory to maximize customer demand fulfillment. The MRP method was chosen as the primary approach in this research. The results of the analysis indicate that the implementation of MRP method with Lot for Lot (LFL) lot sizing is the most efficient choice in controlling raw material inventory. Based on calculations using lot-for-lot and Economic Order Quantity (EOQ) methods, the most efficient inventory expenditure incurred by the company amounts to Rp. 26,274,840. Thus, ordering raw materials with Lot for Lot lot sizing can be used as a solution to optimize the control of aluminum wardrobe inventory in Amal Jaya SME.

Improving Resilience in Water Distribution Systems: An Application of the House of Risk Method at PDAM Gowa Unit Tompobulu

Rahmaniah Malik, Nur Ihwan Safutra, Asrul Fole, Fausan Amal Pangestu — Mon, 29 Jul 2024 00:00:00 +0700

PDAM Gowa, a local government-owned company, plays a vital role in supplying clean water to the Tompobulu community in Gowa District. However, ensuring efficient and reliable water distribution poses challenges at the local and regional levels. This research focuses on enhancing the resilience of the water distribution system to mitigate various risks. The study utilizes the House of Risk (HOR) method for effective risk management and developing suitable mitigation strategies within PDAM's framework. The research identifies 10 risk events and 17 risk factors that affect water distribution in PDAM. Key risks include pipe leakage and supply disruptions. To mitigate these risks, the study proposes nine actionable recommendations for PDAM Gowa Unit Tompobulu. These recommendations involve regular maintenance of distribution infrastructure and equipment to ensure system quality and reliability. Additionally, improving pipe network condition monitoring, implementing leakage control policies, and fostering collaboration with stakeholders to address water supply disruptions are crucial mitigation measures. This research significantly contributes to understanding the risk management associated with water distribution in PDAM. By implementing the recommended mitigation strategies, PDAM Gowa Unit Tompobulu can reduce water distribution risks, enhance system efficiency, and provide improved clean water services to consumers. Moreover, the study has the potential to drive scientific progress and promote the development of best practices and technologies in the drinking water industry.

Evaluation of Container Yard Locations Using Discrete Simulation Method

Roberta Simarmata, Sukaria Sinulingga, Meilita Tryana Sembiring — Mon, 29 Jul 2024 00:00:00 +0700

The loading and unloading process are activity of unloading goods from ships with cranes and then being brought and arranged in temporary warehouses. PT Prima Termina Petikemas is a subsidiary of Pelindo which is engaged in shipping container loading and unloading services. For customer satisfaction, one of the indicators of the company is the truck round time (TRT) which is 33 minutes. Currently, the external truck round time (TRT) for delivery is 43.62 minutes with waiting time by 16.32 minutes and truck round time (TRT) receiving is 37.72 minutes with waiting time by 9.75 minutes. The discrete event simulation method aims to evaluate the determination of effective alternative container yard locations to anticipate truck round time (TRT). For all improvement scenarios carried out, the selected scenario for delivery using 4 blocks and 6 units of Automated Rubber Gantry Tyred (1 unit reach stacker) and the percentage of each block load is 20%. This can reduce the truck round time (TRT) 27.37 minutes with the waiting time is to 8.93 minutes. For receiving activity using 5 blocks and 6 units of Automated Rubber Gantry Tyred (ARTG) and the percentage of each block load is 20%. The waiting time become 9.92 minutes and this reduces the truck round time (TRT) by 33.67 minutes.

Efficiency Strategy for Procurement of Raw Materials for Side Beam for Bogie with Material Requirement Planning at PT XYZ

Rosyid Abdullah, Suseno — Mon, 29 Jul 2024 00:00:00 +0700

Companies in Indonesia must find the right solution in order to survive and compete in the era of globalization. Price competition is an important strategy in the competition between similar companies. Based on this, there is a need for a good understanding in the company regarding strategic financing planning in order to achieve predetermined goals efficiently. This efficiency can be characterized by minimal cost expenditure in order to obtain maximum profit. One way to get maximum profit is by implementing good inventory management PT XYZ is a train manufacturing company in Southeast Asia. The company produces various types of trains. There is a production planning for the Train XYZ project with a total production of 526 units of train components for the Side Beam for Bogie. Procurement of these raw materials, PT XYZ uses Lot for Lot (LFL) at a cost of Rp1,411,402. The use of the LFL system still has shortcomings, namely problems due to late delivery and inefficient procurement in terms of financing. The results of production planning research with several MRP methods that have been compared, it is concluded that POQ lot sizing is the most efficient procurement of raw materials other than LFL. In detail, the total cost with the POQ method amounted to Rp1,243,140 and decreased by 11.9%. The cost consists of procurement costs of Rp781,162 and storage costs of Rp461,978.

Lathe Workshop Layout Design Analysis Using Blocplan and SLP Methods

Jeffri, Uni Pratama Pebrina Tarigan, Anita Christine Sembiring — Mon, 29 Jul 2024 00:00:00 +0700

An inappropriate layout can result in excessive material movement and increase costs significantly. Therefore, it is important to carefully plan the facility layout so that related activities can be coordinated according to the applicable departments and workflows. Sinar Abadi Lathe Workshop is a company engaged in the machining business, especially in the lathe process. This process involves working with materials by cutting or modifying workpieces using a lathe. This research analyses the layout of the lathe workshop using the SLP and BLOCPLAN methods in order to reduce moving costs, and optimism the use of space in the context of the lathe workshop. The implementation of the BLOCPLAN method in the lathe shop showed labor efficiency with less labor required per production cycle compared to the initial layout. However, a complete change from the original layout may result in higher moving costs. This highlights the importance of cost considerations in choosing a layout method. For layout changes with minimal moving costs, the SLP Layout is proposed as a cost-efficient alternative, as it considers various factors, including distance, material transportation, and labor requirements in planning the layout.

Analysis of the Queuing System in XYZ Food Industry in Batam City (Case Study of Queuing Time Observation)

Mon, 29 Jul 2024 00:00:00 +0700

This study analyzes the queuing system at XYZ fast food restaurant in Batam City to improve service efficiency and customer satisfaction. Observations were conducted over eight hours on Saturday, April 6th, 2024, from 2:00 PM to 10:00 PM. Data collected included arrival patterns, service time, and customer wait time. Using the queuing model [M/G/2/FIFO/4/∞], it was found that two servers are optimal. The average customer wait time in the system is 4.938 minutes, which is lower than the customer's aspirational wait time of 10 minutes. The system's utility reached 84.33%, indicating sufficient efficiency. Practical recommendations for XYZ fast food restaurant management are to maintain two servers to reduce wait time and increase customer satisfaction.

Analysis of Extrusion Blow Molding Machine Maintenance Planning with Reliability Centered Maintenance and IRRO Method

Mohammad Bintang Rizqi Pratama, Etik Puspitasari — Mon, 29 Jul 2024 00:00:00 +0700

High demand for plastic products from year to year creates the need for plastic molding machines that can mass produce plastic products. An example of a plastic molding machine used at PT. X is a VK type extrusion blow molding (EBM) machine. Based on data from PT. X, the downtime of the VK type EBM machine reached 215.74 hours in 2021-2023. Therefore, improvements are needed in the machine maintenance management system. The purpose of this research is to determine the critical components, determine the reliability value of the critical components, and also establish a preventive maintenance schedule along with a cost budget plan for each critical component of the VK type extrusion blow molding machine at PT. X to increase the effectiveness of existing production activities. The method used is Reliability Centered Maintenance (RCM) with the application of RCA and FMEA methods to find critical components, then calculate the reliability of critical components as a reference for making preventive maintenance schedules. The data used are the failure data of VK type EBM machine in 2021-2023 period. The results of this study obtained 4 critical components with a reliability value of 0.5, namely the clamping unit at 210.3149 hours, the cutting unit at 79.9911 hours, the head unit at 677.5324 hours, and the hydraulic unit at 424.1550 hours. Maintenance planning is based on the IRRO (Inspection, Repair, Replace, Overhaul) method. The total maintenance cost for the period 2025 is Rp 35,093,903, which reduces the cost by 8.5% compared to 2023.

Analysis of Human Resource Performance Using the Human Resources Scorecard Method in The Production Department at PT. X

Mon, 29 Jul 2024 00:00:00 +0700

PT X is a manufacturing company engaged in the sector of herbal medicines, cosmetics, household supplies, and medical equipment. At PT X there are several problems that can lead to a decrease in the performance of human resources in the company's production department, including the production of capsule drugs that do not reach their targets, a lack of employee motivation at work, and a lack of employee discipline. Based on these issues, PT X is required to implement a performance measurement based on the Human Resources Scorecard (HRSC) method and the Analytic Network Process (ANP) method in order to weight its performance indicators. The objective of this study is to measure the human resource performance of the production department of PT X and determine the performance indicators that require the most improvement. The results of measuring human resource performance using the Human Resource Scorecard indicate that the value of human resource performance in employees of PT X is 2,555613 and it can be concluded that the HR performance is in the not good category because the HR performance value of production department of PT X is in the range of 1,8 - 2,6. The perspective that must be prioritized by PT X in improving its HR performance is the financial perspective because it has the lowest perspective value, precisely on the objective strategy of increasing employee effectiveness because it has the greatest priority weight and the KPI achievement score is very low, which is 1.

Efficient Route Planning for Flour Distribution: A Heuristic Approach

Said Muhammad Baisa, Arif Imran, Hilman Maulana, Alif Ulfa Afifah — Mon, 29 Jul 2024 00:00:00 +0700

This company operates in the Food and Beverage sector, selling Martabak, an Indonesian snack. The company needs to deliver flour to 25 branches spread across Bandung, Indonesia, every day, with varying demand capacities at each branch. Each day, the total amount of flour to be delivered is 377 boxes. Currently, the company has 12 distribution routes with a total distance of 271,16 km, with each route covering only two stores. However, these routes are too many and vehicle capacities need to be optimized, resulting in a high total travelled distance.

The aim of this research is to optimize the delivery routes to reduce the total travelled distance and number of routes. To address this issue, known as the Vehicle Routing Problem (VRP), heuristic methods were employed, specifically the nearest neighbour method for initial route construction and Intra-Route (1-0) Insertion for improvement. Implementing these heuristic methods resulted in a final total of 6 distribution routes with a total distance of 160,90 km. This method successfully reduced the total travelled distance by 110,26 km and reduced the number of routes by 6. In conclusion, the application of heuristic methods in solving the VRP for this company proved to be effective in reducing both the total travelled distance and the number of routes, thereby enhancing the operational efficiency of the delivery process.