KANBAN PRODUCTION SYSTEM DESIGN IN AUTOMOTIVE INDUSTRY

Abstract

This research is about analysis of current system of PT. X in scope of planning, production, control activity. Currently PT. BS Indonesia using push production system principle and having difficulty in some area such as inventory control that is unreliable to provide accurate stock data and scheduling procedure that is not flexible for low inventory planning. In order to improve the overall performance of planning, production, control activity, a study of pull production system of kanban production system is studied and developed. The product observed in this study is backdoor garnish product that have six different variant in colors. For improving the system in scope of inventory control, physical inventory management, and scheduling method, single card kanban system is utilized for improving inventory control and scheduling method. While in physical inventory management improvement is utilizing a combination of principle such as standardized container, dedicated storing, and FIFO policies. After implementation of kanban system trial in November 2013, the number of safety stock is reduced while the number of effective stock slightly changed. Meaning that kanban system can reduce inventory while not increasing supply or delivery shortage potential.