IMPROVING TOWING UNIT OPERATION TO INCREASE PRODUCTION THROUGHPUT RATE AND REDUCE MANUFACTURING LEAD TIME IN PT. X

Abstract

PT. X is one of the automotive compartments producers who implements JIT in their plants including the material handling unit of third plant. Having its responsibility to supply the production line with empty boxes and pulling the finish goods. The whole operation of this towing unit is controlled by the Kanban Cards system in which the towing unit must take or supply the boxes by the exact amount as the Kanban Cards. The planning department is planned that the towing unit cycle time in order to take and supply eight boxes. On the other hand, the towing unit’s operation time is exceeding the 13 minutes which leads to production delay and shortage of material. This leads to inefficiency which production line can only produce 240 units a day. In order to solve this, time study method is conducted in order to reveal the real problem. Solving the problem by using Lean approach, Little’s Law and Capacity Planning Strategies is done and implementation using simulation is commenced. In the end the comparison of models, the output can be increased to 280 units per day and utilization of production can be increased by 17%.