Optimasi Kapasitas Produksi Dalam Penyusunan Jadwal Induk Produksi Menggunakan Integer Linear Programming (ILP) (Studi Kasus di CV. Pabrik Mesin Guntur – Malang)

Christanty, Ellysa Maria Ayu (2014) Optimasi Kapasitas Produksi Dalam Penyusunan Jadwal Induk Produksi Menggunakan Integer Linear Programming (ILP) (Studi Kasus di CV. Pabrik Mesin Guntur – Malang). Sarjana thesis, Universitas Brawijaya.

Abstract

Perencanaan produksi yang baik sangat dibutuhkan CV. Pabrik Mesin Guntur dalam memenuhi jumlah permintaan (order) produk berupa mesin pompa air dari konsumen. Pabrik memiliki perencanaan produksi dalam bentuk program produksi untuk mengatur jumlah produksi mesin pompa air yang menjadi target order. Saat ini, program produksi yang dibuat pabrik tidak memperhitungkan perbandingan antara kapasitas yang dibutuhkan dengan kapasitas yang tersedia dalam menentukan jumlah produksi optimal untuk mencapai target order. Hal ini berpengaruh pada laju produksi pabrik yang menyebabkan masih adanya produk work in process dan menghasilkan sisa order produksi (SOP) yang cukup banyak untuk periode selanjutnya. Oleh karena itu, pabrik membutuhkan solusi optimal untuk mengelola sumber daya dalam menyeimbangkan kapasitas produksi yang tersedia di stasiun kerja guna meminimalkan SOP. Dengan demikian, pabrik dapat menentukan jumlah produksi dengan total profit maksimal yang disusun dalam jadwal induk produksi (JIP) optimal. Penelitian ini menggunakan metode perhitungan integer linear programming (ILP). Penerapan metode ini digunakan untuk mengoptimalkan kapasitas produksi pada stasiun kerja mesin pompa air. Langkah-langkah yang dilakukan antara lain mengelola kapasitas yang tersedia pada stasiun kerja untuk menentukan jumlah produksi dengan tujuan meminimasi SOP serta menghasilkan total profit yang tinggi, meningkatkan kapasitas di stasiun kerja yang menjadi kendala karena kapasitasnya tidak mencukupi untuk memenuhi target order dengan pemilihan alternatif antara penambahan jam kerja (lembur) atau penambahan resources, kemudian dari keduanya dipilih melalui output perhitungan ILP dengan hasil SOP paling minimal dan total profit paling tinggi. Berdasarkan hasil pengolahan data menggunakan integer linear programming (ILP) dapat diketahui adanya 4 (empat) stasiun kerja yang menjadi kendala karena kapasitas yang tersedia belum mencukupi kapasitas yang dibutuhkan untuk memenuhi target order bulan Juni 2014 dengan prioritas pemenuhan SOP bulan Mei terlebih dahulu. Stasiun kerja (SK) tersebut antara lain stasiun kerja proses frais (SK-2), stasiun kerja proses stick (SK-6), stasiun kerja proses perakitan (SK-7), dan stasiun kerja proses pewarnaan (SK-8). Oleh karena itu, perlu dilakukan peningkatan kapasitas dengan memutuskan adanya penambahan jam kerja (lembur) yang dialokasikan seimbang pada stasiun kerja kendala. Hasil perhitungan ILP dengan penambahan jam lembur menghasilkan minimum SOP dalam memenuhi SOP bulan Mei sebanyak 8 unit produk mesin pompa air, SOP target order bulan Juni 2014 sebanyak 248 unit, serta dari jumlah produksi optimal untuk bulan Juni 2014 didapatkan total profit sebesar Rp. 457.027.300,-. Sehingga dari output perhitungan ILP dapat disusun pada jadwal induk produksi (JIP) bulan Juni 2014 yang optimal sesuai dengan kapasitas yang dimiliki pabrik.

English Abstract

Good production planning is needed by CV. Pabrik Mesin Guntur in meeting the demand products such as water pumps from consumers. The factory has a production planning in the form of the production program to regulate the amount of production water pump engine targeted orders. Currently, the production program made by the plant does not consider the ratio between the required capacity to available capacity in determining the optimal amount of production to achieve the target order. This affects the production rate of the plant which led to the persistence of the products work in process and generate the rest of the order of production (SOP) which is pretty much for the next period. Therefore, plants need an optimal solution to manage resources in balancing production capacity available at the work station in order to minimize the SOP. Thus, the plant can determine the amount of production with the maximum total profit arranged in the master production schedule (MPS) optimal. This study uses the integer linear programming (ILP) methods. This method is used to optimize the production capacity at the pumps water work station. Stages performed in this study are managing capacity available at the work station to determine the production with the goal of minimizing the number of SOPs and to produce a total high profit, increasing capacity at the work station is a constraint because of insufficient capacity to meet the target of the order with the alternative choice between an extra working hours (overtime) or addition of resources, and then selecting from the output calculation results of ILP with the most minimal SOP and total profit highest. Based on the results of data processing using the integer linear programming (ILP) obtain that there are 4 (four) constraints work stations. Since the May’s SOP became priorities, the capacity is not sufficient to meet the target order in June 2014. Work stations that has not sufficient capacity are work stations milling process (SK-2), the stick work station (SK-6), work station assembly process (SK-7), and the staining process work stations (SK-8). Therefore, it is necessary to increase the capacity to decide the additional working hours (overtime) allocated balance constraints at the work station. ILP calculation result with the addition of overtime hours generates a minimum SOP, in meeting May’s SOP of 8 water pumps products and SOP targets order in June 2014 as many as 248 units. The optimal production quantity for the month of June 2014 obtained the profit of Rp. 457 027 300, -. The calculation of the output ILP can be arranged on the master production schedule (MPS) in June 2014 which is optimal according to the capacity of the plant.

Item Type: Thesis (Sarjana)
Identification Number: SKR/FT/2014//658/051407394
Subjects: 600 Technology (Applied sciences) > 670 Manufacturing
Divisions: Fakultas Teknik > Teknik Industri
Depositing User: Hasbi
Date Deposited: 14 Nov 2014 08:42
Last Modified: 10 Nov 2021 06:28
URI: http://repository.ub.ac.id/id/eprint/142357
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