Tekinfo: Jurnal Ilmiah Teknik Industri dan Informasi

Increasing Efficiency with the VSM Method to Reduce Waste in the Line Assembly of the Wooden Ship Process Production

2023-01-27T14:27:24+00:00

Monas Home Industry is one of the home industries in Tegal. Monas Home Industri produces ships from wood called wooden ships. The name of the ships is “kapal cantrang”. The system of production of Kapal Cantrang is make to order. It means Monas will produce if there is any order from customer. The problem occurs when Monas Home Industry cannot fulfill customer order ontime. The purposes of this study are to identify the types of waste and improve waste through the lean manufacturing concept. The Value Stream Mapping (VSM) is carried out to mapping a detailed value stream. Mapping process begins with identification the initial concept of the map then analysis of waste. As the results, there are three kinds of waste, that are: Processing (19%), Defect (18%), and Movement (17%). Before improvement, the percentage of transportation time was 1.7%, including the necessary but non added value category. Then, the Value Added Ratio was 97.2%. The PAM percentage after improvement became 1.2% and the VAR value became 98%.

Keywords: Lean Manufacturing, Value Stream Mapping, Wooden Vessels

Ergonomic Risk Analysis Using Agricultural Whole-Body Assessment (AWBA) and Prevalence of Musculoskeletal Disorders (MSDs) in Rubber Farmers

2023-01-27T14:27:22+00:00

Likewise in most agricultural work, MSDs also appears in rubber farmers because it was done with an unusual posture. This study aimed to evaluate the prevalence of MSD and to analyze the ergonomic risk of rubber farmers working posture. The NBM (Nordic Body Map) method was used to measure the prevalence of MSDs and the AWBA (Agricultural Whole-Body Assessment) method was used to calculate the risk value of the farmer's work posture. Data collected by interview and direct observation to 15 rubber farmers from 4 different plantation in Perangat Selatan Village, Kutai Kartanegara, East Kalimantan. The results showed that majority of farmers had complaints of MSDs on their waist, back, right shoulder, right upper arm, right forearm and knee. AWBA results indicated that 53% working posture categorized as high risk; 40% as medium risk and 7% as safe. The safe category only occurs in sharpening knives activity, because farmers sit while doing this activity. Suggested improvements to minimize the risk of unusual postures are to provide assistive devices such as light chairs, strollers, tables to place rubber sap to be put into sacks and to improve the design of the tapping knife. The knife should have longer handle in order to minimize the bending down posture in rubber tapping activity.

Keywords: AWBA, ergonomic, NBM, rubber farmers, working posture

Assessment of Work Posture on Chips Frying Section Workers

2023-01-27T14:27:19+00:00

The postures of frying workers when they do their activities are back bent, the body twists to the right and left, and the arm reachs too wide. The work activities are putting slices of tempe in a frying pan, and frying and draining tempe. From the interview, we know that workers felt the most pain in the buttocks/thighs and back. The pain happens because workers do their activities in a static position for a long time. It causes complaint to the skeletal muscle system. The purpose of this study are to find out the complaints that felt by workers, find out the work posture in accordance with ergonomics rules or not, and find out how big the level of risk is. The methods used in this study were Nordic Body Maps (NBM) questionnaire, Rapid Upper Limb Assessment (RULA) method and Rapid Entire Body Assessment (REBA) method. The results of the analysis using the NBM questionnaire showed that 50% workers felt pain in their shoulders, 50% in their lower back,60 % in their buttocks/thighs, and 50% in their knees. The second conclusion of the NBM questionnaire was the work posture of frying workers did not match with the ergonomics rules. The results of the RULA assessment shows the work activity of the frying department was 7. This level was very high level, while the results of the REBA assessment show a very high risk with a score of 11. Further actions needed are investigating and immediating change actions. Improvements that can be made for workers are using a chair with a backrest, doing stretching movements to reduce the pain felt in the limbs, and rearranging the work area.

Keywords: work posture at frying station, Nordic Body Maps, RULA, REBA

Determination of the Spare Parts Inventory Optimum Level at PT. XYZ Using Minimum Maximum Stock Level (MMSL)

2023-01-27T14:27:17+00:00

XYZ company in Sumatera area is operating in the business of oil palm plantation and oleochemicals processing. Its production is based on the supply of mostly from company-owned plantation. In this push system of raw material, production runs continuously resulting the reliability of the machine becomes essential. Material and spare part that support machine cannot be replenish at time when it needed. Thus, overstock can be due to the high cost of storing as well as the risk of storing products. This study aims to calculate minimum and maximum level of inventory that have been the most often stockout occur. The calculation is carried out by Minimum-Maximum Stock Level (MMSL) method on refillable oxygen, turalik oil, steel nut bolt 3/4x3”, steel nut bolt 3/4x4”, welding wire RB 26 dia. 3.2 mm and welding wire LB 52 dia. 3.2mm. MMSL in this study accommodate basic economic order quantity (EOQ). Calculation displays the minimum level, mximum level and optiml order quantity for all six materials. The results are then compared with the actual data and it was found that high fluctuations caused the minimum level results to be in high level and the range between the minimum-maximum levels becomes narrow. One aspect of the reckoning is the demand rate which is calculated by dividing the annual demand by the number of working days. Such justifications should not be used on data with high fluctuations. Therefore, MMSL with basic EOQ should be used on data with small standard deviation

Keywords: level minimum, level maximum, safety stock, economic order quantity

Work Posture Analysis using the Quick Exposure Check Method at PT XYZ

2023-01-27T14:27:15+00:00

PT XYZ is a Machining-Engineering and Fabrication service provider company located in the Jababeka Cikarang Industrial Area. PT XYZ has 5 production workstations, namely a CNC lathe machine workstations, Two CNC milling stations, namely CNC milling 1 and CNC milling machines 2, and two manual machine stations, namely Centerless Grinding 1, and Centerless Grinding 2. When carrying out production activities, workers must pay attention to safety and work posture because non-ergonomic body movements can cause injury. Therefore, this study aims to detect PT. XYZ’ workstations that are not ergonomic and identify work postures of workers' bodies parts that are risk of Musculoskeletal Disorders complaints by the Quick Exposure Check method. This method was chosen because the assessment is carried out based on two points of view, namely observers and workers to minimize bias in subjective judgments. Based on the results of research on 5 workers, the research results obtained 3 workstations that are not ergonomic. This is because the action level at the workstation is at a range of 71-100% which is included in level 4 so corrective action is needed right now. 2 workstations have a high risk of experiencing Musculoskeletal Disorders in the back, wrists, and neck. Whereas 1 workstation has a very high and high risk of experiencing complaints of Musculoskeletal Disorders in the neck and wrists. Thus, it is necessary to propose actions to improve work posture so that workers can work ergonomically.

Keywords: Musculoskeletal Disorders, Quick Exposure Check, Work Posture

Analysis Of Planning and Control Of Raw Materials Supplies using The Economic Order Quantity Method

2023-01-27T14:27:13+00:00

CV Bintang Timur Graphic is a company that produces learning tools for schools with a make-to-order production system. However, the ups and downs of production capability and capacity are one of the variables in inventory planning and control that needs to be controlled. Inventory control activities are very important for the company. If there is a stockout, the company cannot meet customer needs. Because consumer demand often fluctuates, especially in terms of quantity, type, or frequency. The inventory policy implemented at CV Bintang Timur Graphic does not use past historical data so excess or shortage of inventory often occurs. This study aims to analyze the number of raw material supplies, to be able to provide effective and efficient planning. The method used is the Economic Order Quantity (EOQ). The proposed inventory control plan using the EOQ method provides significant cost efficiency. Based on the results of the EOQ, 3 items have the highest efficiency ratings, including CD paper, which can save up to 81% of inventory costs, HVS Indigo Roll 73, which can save up to 72% of inventory costs, and 58.5x84 size paper, which can save up to 53% of inventory costs. For other raw material items, the average cost-saving efficiency reaches 35%. Then the application of the Economic Order Quantity (EOQ) method is appropriate for inventory control at CV Bintang Timur Graphic.

Keywords: Efficiency, Fluctuation, Frequency, Make to Order, Production

Effectiveness Analysis of the Implementation of Operation Breakdown (OB) at PT. Dan Liris through Cycle Time Evaluation with Continuous Improvement Method

2023-01-27T14:27:11+00:00

PT. Dan Liris has a problem with the production system. Operation Breakdown (OB) is an example of a problem that occurs and has an impact on achieving production targets, delivery accuracy, and product prices. Based on the observations, there was a time mismatch at OB in the production process. The Continuous Improvement method was used as a research method in solving this problem. The data collected by observations, interviews, and literature studies. This research was conducted with the repeated production orders at least three times. Based on the collected data, the actual cycle time were obtained, which were compared with the OB. The data obtained become the basis for determining the solution. The root causes obtained were grouped into five main factors, namely man, machine, method, material, and environment. Of the five factors, two factors that could be used to solve the problem are the man factor and the method. The proposed improvements were the creation of a priority form, a checklist form for the use of machines and attachments, an output form, and the addition of a leadership training agenda. After testing and evaluating the implementation of the improvements, it was found that the forms submitted needed to be revised so that a digital form template was obtained as the final solution that could be used.

Keywords: 5M, cycle time, continuous improvement, leadership, operation breakdown