Perencanaan Kapasitas Produksi AC (Air Conditioner) dengan Metode Rough Cut Capacity Planning di PT. INKA

Wardani, Anggraini Wisnu (2017) Perencanaan Kapasitas Produksi AC (Air Conditioner) dengan Metode Rough Cut Capacity Planning di PT. INKA. Sarjana thesis, Universitas Brawijaya.

Abstract

Kenaikan jumlah penumpang kereta api dari tahun 2013 sampai 2015 cukup signifikan, dari tahun 2013 – 2014 naik sebesar 28% dan dari tahun 2014 – 2015 naik sebesar 17%. PT. INKA yang merupakan produsen tunggal kereta api menerima permintaan pembuatan kereta di tahun 2017 lebih tinggi dibandingkan tahun sebelumnya. Fasilitas didalam garbong kereta khususnya kereta penumpang adalah AC (Air Conditioner). AC kereta penumpang tahun 2017, berbeda dari yang AC sebelumnya. Perbedaanya yaitu ukuran AC tahun 2017 dua kali lebih besar dibandingkan AC sebelumnya sehingga dalam 1 gerbong akan dipasang 1 buah AC saja. Saat ini, workshop AC mampu merakit 220 unit AC sedangkan target pembuatan kereta penumpang sebanyak 510 gerbong dan workshop AC harus membuat sesuai dengan jumlah kereta penumpang yaitu 510 unit AC. Kapasitas tersedia saat ini lebih rendah dibandingkan permintaan kereta jika tidak teratasi akan berdampak pada keterlambatan pengiriman gerbong dan akan dikenakan denda dari konsumen. Pada penelitian ini dilakukan pengukuran kerja untuk mengetahui kapasitas yang dibutuhkan untuk merakit AC sesuai target 2017. Aktivitas pengukuran waktu kerja dalam penelitian ini dilakukan secara langsung pada 10 workstation perakitan AC dengan menggunakan metode Stopwatch Time Study. Perhitungan waktu standar pada perakitan AC dimulai dengan menyusun elemen kerja. Kemudian menetapkan nilai kelonggaran berdasarkan rekomendasi ILO (International Labour of Organization), sedangkan dalam menentukan nilai Performance Rating menggunakan Westinghouse’s. Perhitungan dan perencanaan kebutuhan kapasitas dihitung menggunakan metode Rough Cut Capacity Planning dengan menggunakan teknik Bill of Labour. Hasil perhitungan kapasitas setiap minggu terdapat beberapa elemen kerja yang belum bisa memenuhi kapasitas yang dibutuhakan sesuai dengan target tentative schedule yang telah dibuat oleh PT INKA. Terdapat 7 elemen kerja yang masih mengalami kekurangan kapasitas tersbesar. Strategi pemenuhan kapasitas sesuai target tahun 2017 yaitu dengan penambahan jam lembur atau over time tetapi masih mengalami kekurangan kapasitas kemudian ditambah alternatif over time + ekstra day (jam lembur di hari Sabtu). Menggunakan alternatif over time + ekstra day masih mengalami kekurangan kapasitas kemudian dilakukan alternatif over time + ekstra day + penambahan alat dan pekerja pada beberapa workstation yang selisih kapasitasnya masih besar dan masih mengalami kekurangan kapasitas, alternatif selanjutnya adalah melakukan revisi tentative schedule dari alternatif ketiga sehingga kapasitas yang dibutuhkan dapat terpenuhi. Alternatif lain selain keempat alternatif sebelumnya yaitu penambahan shift kerja tetapi dengan alternatif ini masih mengalami kekurangan kapasitas lalu dikombinasikan dengan penambahan alat dan tenaga kerja. Hasil perhitungan dengan menggunakan beberapa strategi tersebut dapat memenuhi kapasitas yang dibutuhkan sesuai target tahun 2017 dan terdapat sisa jam yang digunakan jika terjadi keterlambatan kedatangan komponen atau material AC.

English Abstract

The increase of the train passengers amount from 2013 to 2015 was quite significant, from 2013 – 2014 up by 28% and from 2014 to 2015 up by 17%. PT.INKA, which is the train single producer, approved a higher demand of train production rather than in the previous year. The facility inside the wagon, especially in the passenger train is AC (Air Conditioner). The AC in the passenger train in 2017 is different from the AC in the previous year. The difference is the AC size in 2017 twice bigger than the previous AC so within 1 wagon, there will be only 1 AC. Nowadays, AC workshop is able to make 220 unit AC, meanwhile passenger train target production is 510 wagons and the AC workshop has to suitable with the amount of passenger trains, which are 510 units AC. The available capacity is currently lower than train demand, and if it is not resolved, it will have an impact on the delay of train shipping and will be defined by the customer. This research conducted work measurement to know the capacity needed for assembling the AC based on the target on 2017. Work time measurement activity in this research has done directly on 10 AC assembly workstations, started with a Stopwatch Time Study method. The standard time calculation in the AC assembling started to compile the work element. Then, determining the leniency value based on ILO (International Labour of Organization) recommendation, meanwhile in determining Performance Rating value used Westinghouse’s. Calculation and planning of necessity capacity calculated by Rough Cut Capacity Planning method by using Bill of Labour technic. The result of the capacity calculation in every week, there were some work elements which cannot fulfill the capacity needed according to the tentative schedule target which already made by PT.INKA. There were 7 work elements which were still experiencing the greatest capacity shortage. Capacity fulfillment strategies according to the 2017 target were added by overtime work, but still experiencing the lack of capacity, then added by over time + extra day work on Saturday as the alternative. Using the overtime + extra day alternative still experiencing the lack of capacity, then another alternative has made, which was the overtime + extra day + addition of the tools and workers in some workstations which the capacity difference was still high and still experiencing the lack of capacity. And the next alternative was revising the tentative schedule from the third alternative, so the needed capacity could be fulfilled. Another alternative has found besides the other four previous alternatives. This alternative was the addition of work shift, but this alternative was still experiencing the lack of capacity and then was combined with the addition of tools and the workers. The counting result by using those strategies could fulfill the capacity which was needed according to the target in 2017 and there was the remaining time which could be used if there was arrival delay of AC component or the AC material.

Item Type: Thesis (Sarjana)
Identification Number: SKR/FT/2017/663/051707256
Uncontrolled Keywords: Perencanaan Kapasitas, AC (Air Conditioner), Rough Cut Capacity Planning, Bill of Labour
Subjects: 600 Technology (Applied sciences) > 629 Other branches of engineering > 629.04 Transportation engineering
Divisions: Fakultas Teknik > Teknik Industri
Depositing User: Budi Wahyono Wahyono
Date Deposited: 25 Aug 2017 09:04
Last Modified: 02 Dec 2020 10:45
URI: http://repository.ub.ac.id/id/eprint/1726
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