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THIS IS THE INSTRUCTIONS FOR WRITING THESIS AT INDUSTRIAL ENGINEERING PROGRAM PRESIDENT UNIVERSITY
(Center, Times New Roman 16 bold, Single line spacing, no adding space between lines) 6 single space, TNR 16 (can be adjusted if the title is too long)
By Johan Oscar ID No. xxxxxxxxx (Center, Times New Roman 14 bold, Single line spacing, no adding space between lines) 5 single space, TNR 14
A Thesis presented to the Faculty of Engineering President University in partial fulfillment of the requirements of Bachelor Degree in Engineering Major in Industrial Engineering (Times New Roman 14 bold) 6 single space, TNR 14
2012 (Times New Roman 14 bold)
THESIS ADVISOR RECOMMENDATION LETTER (Center, Times New Roman 16 bold, 1.5 line spacing, no adding space between lines)
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This thesis entitled “Increasing Line Efficiency in W1234 by using Time Study and Line Balancing (A case study in PTXI)” prepared
and submitted by Yosi Twentiarani in partial fulfillment of the requirements for the degree of Bachelor Degree in the Faculty of Engineering has been reviewed and found to have satisfied the requirements for a thesis fit to be examined. I therefore recommend this thesis for Oral Defense. (TNR 14pt, 1.5 space, no adding space between lines)
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Cikarang, Indonesia, January 31 , 2012
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Herwan Yusmira, Bsc. MET, MTech. (Advisor name)
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DECLARATION OF ORIGINALITY
I declare that this thesis, entitled “Increasing Line Efficiency in W1234 by using Time Study and Line Balancing (A case study in PTXI)” is, to the best of my knowledge and belief, an original piece
of work that has not been submitted, either in whole or in part, to another university to obtain a degree.
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Cikarang, Indonesia, January 31 , 2012
Yosi Twentiarani
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INCREASING LINE EFFICIENCY OF W1234 BY USING TIME STUDY AND LINE BALANCING (A case study in PTXI) (Center, Times New Roman 16 bold, 1.5 line spacing, no adding space between lines)
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By Yosi Twentiarani ID No. 00420080023 1 enter 1.5 space, TNR 14
Approved by
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Herwan Yusmira, B.Sc. MET, MTech Herwan Yusmira, B.Sc. MET, MTech Thesis Advisor Program Head of Industrial Engineering (TNR 12, 1.5 line spacing)
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Dr.-Ing Erwin Sitompul Dean of the Faculty of Engineering
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ABSTRACT 2 enter 1.5 space, TNR 12
Abstract should be written not more than 200 words in Times New Roman 12 pt with 1.5 line spacing. Abstract should include all of the research, starting from background, research methodology, and the results. At the end of this abstract has to be provided with at least six keywords. Keywords: at least six keywords
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ACKNOWLEDGEMENT 2 enter 1.5 space, TNR 12
This thesis is hardly to be done without a big support. Therefore, I would like to express my gratitude to: 1. Jesus Christ, the source of everything. Thank you for unconditional love that You have given to me. 2. My family. Thank you for believing and loving me. I l ove you all. (Times New Roman 12pt with 1.5 line spacing, no adding space between lines)
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TABLE OF CONTENTS
THESIS ADVISOR RECOMMENDATION LETTER ....................................... i DECLARATION OF ORIGINALITY ................................................................. ii APPROVAL PAGE .............................................................................................. iii ABSTRACT .......................................................................................................... v ACKNOWLEDGEMENT .................................................................................... vi TABLE OF CONTENTS ...................................................................................... vii LIST OF TABLES ................................................................................................ ix LIST OF FIGURES .............................................................................................. x LIST OF TERMINOLOGIES ............................................................................... xi CHAPTER I INTRODUCTION .......................................................................... 1 1.1. Background ............................................................................................ 1 1.2. Problem Statement ................................................................................. 4 1.3. Objectives............................................................................................... 4 1.4. Scope ...................................................................................................... 5 1.5. Assumption ............................................................................................5 1.6. Research Outline .................................................................................... 5 CHAPTER 2 LITERATURE STUDY................................................................. 9 2.1. Vehicle Routing Problem ....................................................................... 9 2.1.1
Definition ...................................................................................... 9
2.1.2
Basic VRP Model.......................................................................... 10
2.1.3
2.1.2.1
Travelling Salesman Problem ........................................... 10
2.1.2.2
Set Part Partitioning .......................................................... 11
VRP Classifications ...................................................................... 12
2.2. Vehicle Routing Problem with Time Window (VRPTW).......................14 2.3. Vehicle Routing Problem with Multiple Trips (VRPMT) ...................... 15 CHAPTER III RESEARCH METHODOLOGY ................................................. 33 3.1. Initial Observation .................................................................................. 33 3.2. Problem Identification ............................................................................ 34 3.3. Literature Study ...................................................................................... 36
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3.4. Data Collection and Calculation ............................................................ 36 3.4.1 Data gathering and observation ......................................................... 36 3.4.2 Data tabulation and calculation ......................................................... 36 3.5. Analysis .................................................................................................. 37 3.6. Conclusion and Recommendation.......................................................... 37 CHAPTER IV DATA ANALYSIS ...................................................................... 38 4.1. Initial Efficiency..................................................................................... 38 4.2. Improvement through Kaizen 555 ......................................................... 39 CHAPTER V CONCLUSION AND RECOMMENDATION ............................ 78 5.1. Conclusion.............................................................................................. 78 5.2. Recommendation.................................................................................... 79 REFERENCES...................................................................................................... 80 APPENDICES ...................................................................................................... 81 Appendix 1 Picture of Equipments ........................................................ 81 Appendix 2 OPC of W1234 before Observation ................................... 86
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LIST OF TABLES 2 enter 1.5 space, TNR 12
Table 3.1 Comparison table among four techniques of work measurement .... 3-3 Table 3.2 Westinghouse System Scoring ......................................................... 3-4 Table 4.1 Performance factor calculation ........................................................ 4-1
(The table should be ordered by number of chapter and followed by the sequence of the table in that chapter. For instance, Table 3.1 can be found in chapter 3 and the first table in chapter 3)
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LIST OF FIGURES 2 enter 1.5 space, TNR 12
Figure 3.1 Example of Operation Process Chart ............................................... 3-3 Figure 3.2 An example of precedence diagram ................................................. 3-4 Figure 4.1 Flowchart of simulation making ...................................................... 4-1
(The figure should be ordered by number of chapter and followed by the sequence of the figure in that chapter. For instance, Figure 3.1 can be found in chapter 3 and the first figure in chapter 3)
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LIST OF TERMINOLOGIES Balance delay : the amount of idle on production assembly lines caused by the uneven division of work among operators and stations
Cycle time
: the period required to complete one cycle of an operation, or to complete a function, job, or task from start to finish
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CHAPTER I INTRODUCTION (TNR 16, 1.5space) 2 enter 1.5 space, TNR 12
1.1.Problem Background
Having high efficiency is very beneficial for a company. One of the benefits is related to the internal of the company itself. When the efficiency is high, it means that all resources such as men, raw material, machines, and space are wellutilized. Thus, excess resources can be allocated for other projects. Moreover, the company could also spend proper cost of production when the efficiency is high. Another benefit is increase the value of the company in the midst of business competition. The company will be able to produce more output with a shorter lead time in fulfilling demand from customers. Those are some benefits of having high efficiency.
1.2.Problem Statement
The background of the problem leads into the statement below. •
What is the root cause of having low line efficiency in costume sewing of W1234?
•
How to increase the line efficiency in costume sewing of W 1234?
1.3.Objectives
The main objective of this research is to increase the line efficiency in from 57.6% into 90%. Absolutely, it also means that the target output will be achieved, 500 finished costumes a day. Thus the overtime will be eliminated. By doing this final project, there are some secondary objectives could be achieved. Those are: •
Removing hand-to-mouth system
•
Reducing cost of production
1.4.Scope
Due to limited time and resources in doing this research, there will be some scope in the observation:
1
•
The observation is only done in dress part of W 1234.
•
This project is done in October, 12 -20, 2011.
•
Adding or eliminating sewing operator could be executed by Sewing Production Department.
1.5.Assumption
Some assumptions have to be made in order to run this model properly. •
There will be no defect in the midst of sewing process.
•
The target output is always the same.
1.6.Research Outline Chapter I
Introduction
This chapter consists of the background of final project, project identification, objective, scope and assumption of the study. Chapter II
Literature Study
This chapter delivers the previous study about time study, line balancing, and other tools which support this final project. Chapter III
Research Methodology
The flow of this final project is explained in this chapter. Chapter IV
Data Analysis
The data observation is processed and analyzed in this chapter. The result of data analysis is a new arrangement of line W 1234 which expected to increase the line efficiency. Chapter V
Conclusion and Recommendation
This chapter will give the conclusion result of this final project, and also recommendation for future research.
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CHAPTER II LITERATURE STUDY
2.1.Normality Test
Beside the normality, the uniformity of the data also needs to be examined. A set of data may fulfill the law in normality test but the variance is too wide. Thus the data is significantly different one another. Therefore, a limit must be created in this test to make sure that all data is in expected range area. If it is found a data outside the limit, that data must be removed. These are the steps to determine the uniformity of a set of data:
̅
a. Calculate average observed time ( ) for each operation.
∑ ̅ =
(2-1)
b. Calculate the standard deviation (s) of each operation (Wignjosoebroto, 2000).
( ̅ ) = ∑
(2-2)
( All equations have to be numbered by number of chapter following the order of the equation in the chapter. For instance, equation 2-1can be found in chapter 2 and located at the second equation).
( All table, figures, drawings and half-tone illustrations (pictures) should, as far as possible, appear in appropriate place within the body of the text, and must be in a form suitable for printing. The alignment of a figure is in center and in left for a table. Figures should be in frameless format)
Table 4.1 Sewing line efficiency of W1234 (TNR 11pt bold) Overtime
Output
Line
(hours)
(in thousand)
Efficiency
9 9 9
16 16 34
0.3 0.375 0.5
44.6% 55.8% 61.8%
9
30
0.5
64.2%
141
2.535
Date
Operator
10-Oct-11 11-Oct-11 14-Oct-11 15-Oct-11 Total
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Initial Observation in Kaizen 555 120 100 ) s 80 ( e 60 m i T 40
Initial Observation in Kaizen 555
20 0 1
2
3
4
5
6
7
8
9
Workstation
Figure 4.1 Yamazumi Chart of W1234 in the initial observation by Kaizen 555 team (TNR 11pt Bold)
Citing References •
•
•
•
•
The references should be listed in the alphabetical order of the author names and in the order of the publication years within the same author’s works. Each reference should be written in the order of the authors, the publication year, the title or source. Journal names, names of conferences, proceedings, and book titles should be italicized and should have the first character of each word uppercase, except for the conjunctions and articles. The article title should be written between apostrophes, e.g., ”The Example of….” and should have the first character of each word uppercase, except for the conjunctions and articles. The volume, series and pages are written consecutively. The three or more authors of a reference should be written as the first author followed by 'et al.', for instance, (Forza et al.,1993) at the end of a sentence, Forza et al. (1993) in a sentence. It is recommended to avoid referring a Web source since the availability is not secured. If there is an official document source, for instance, a journal paper, for the same document, please refer the official document. However, you may sparingly use Web sources. In the case, when available, the title, the author name, and the year should be clarified in addition to the detailed address.
References
Forza, C., Vinelli, A., and Filippini, R., Telecommunication Services for Quick Response in the Textile-Apparel Industry, Proceedings of the 1st International Symposium on Logistics, The University of Nottingham, 1993, pp. 119-26.
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Holmes, C. C., and Mallick, B. K., Generalized Nonlinear Modeling with Multivariate Free-Knot, Journal of the American Statistical Association, 98(462), 2003, pp. 352-365. Klir, J., and Yuan, B., Fuzzy Sets and Fuzzy Logic : Theory and Applications, Prentice-Hall, New Delhi, 2001. Lyche, T., and Morken, K., Spline Methods, Draft, 2004, retrieved from http://www.ubuion./umn/english/index.html on 09 November 2009. Mallian, H., Studi Literatur tentang Model Peramalan ARMA ( p,q) dan Selang Keper-cayaan Parameter Model dengan Menggunakan Bootstrap , Tugas Akhir, Jurusan Teknik Industri, Universitas Kristen Petra, Surabaya, 2006.
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