Peningkatan Efisiensi Lintasan Produksi Lemari di Karangsari Furniture Menggunakan Metode Dynamic Programming

Abstract

Line imbalance in production systems is one of the major issues in the manufacturing industry, as it can lead to bottlenecks, increased cycle times, and decreased efficiency and productivity. This problem affects the optimal allocation of workloads at each station, resulting in high idle times and reduced production output. This study was conducted at Karangsari Furniture, a company that produces various types of furniture, focusing on wardrobe production as the object of study. The issue was identified across six work centers, with particular concern at the gluing station (work center III), which had the highest cycle time of 3,109 seconds, thus creating a bottleneck in the overall production process. The objective of this research is to analyze the initial line balance condition using the Region Approach (RA) method and propose improvements through a Dynamic Programming (DP) approach. Data collection was carried out through direct field observation, interviews with operators, and cycle time measurements using a stopwatch, followed by data adequacy and uniformity testing to ensure reliability. The balancing results using the Region Approach resulted in 5 workstations and showed a line efficiency of 46.81%, a balance delay of 52.57%, and a smoothing index of 4,286.2653. Meanwhile, the Dynamic Programming approach resulted in 4 workstations and showed improved line efficiency of 58.52%, a reduced balance delay of 40.71%, and a smoothing index of 3,027.2381. These findings indicate that the Dynamic Programming approach provides more optimal results in balancing the production line and successfully improves the efficiency of the wardrobe production process. The implementation of this method is expected to enhance efficiency, minimize time waste, and strengthen the company's competitiveness amid the increasingly intense manufacturing industry landscape.