INCREASING THE CAPACITY PACKOUT PROCESS AT TOY MANUFACTURING

Abstract

In manufacturing companies, the company's ability to face every challenge is very important to remain competitive in the business world. Toy Manufacturing is one of the largest manufacturing companies in Indonesia, located in West Java. Toy Manufacturing has a new product called FP toy produced from October 2020 to March 2021. The forecast orders for FP toy that will be produced by the company is increasing every month. The problem that occurs in this company is that an increase in demand must be covered while the actual production of FP output is lower than demand. To solve this problem the author designed the jig and workstation. The purpose of jig and workstation design is to reduce cycle time in the production process packout of FP to increase the capacity. The method used to determine jig and workstation design is Quality Function Deployment (QFD) to translate operator needs and provide solutions according to the capacity that can be met. The data collection was carried out through Focus Group Discussion (FGD), interviews, and direct observation. Some of the tools used in this study include the House of Quality (HOQ), screening, and scoring. The results of this study are in the form of jigs and workstations that can increase the efficiency of the FP production process packout from 80% to 94%, increasing the output from 1600 toys to 1880 toys in 8-hours production. Besides, jigs and workstations make it easier for operators to work in packout process production FP.