Abstract:
PT ABC, a toy manufacturing company, is confronting generation challenges due
to the developing variety of products and expanding market demand. This
challenge caused various alterations to the production layout, driving to a rise in
setup time from 20 minutes to 40-60 minutes, with an normal of 800 changeovers
per week. This condition essentially impacts Manufacturing Lead Time (MLT).
The first hour of production results showed a non-achievement of the target
production caused by several issues such as frequent machine changes, material
shortages, and related workers. To handle these issues, Agglomerative
Hierarchical Clustering (AHC) was connected to group production lines based on
machine usage, pointing to streamline moves and progress asset dispersion.
Utilizing XLStat program, 100 products were analyzed, coming about in five
clusters assigned to five separate production lines. A trial conducted in August on
Line G showed a decrease within the changeover layout ratio by evaluating total
changeover and total sku per line from 2.7 to 1.7 driving to a decrease in week
after week changeovers from 800 to around 400 in November. Moreover, the usage
of the Single Minute Exchange of Dies (SMED) strategy made a difference refine
the changeover process, cutting setup time by roughly two minutes. These comes
about highlight that AHC and SMED can effectively reduce setup time and
improve production flow despite increasing product complexity.
