Penerapan Theory of Constraint (TOC) untuk Penyeimbangan Lintasan Produksi pada Divisi Sewing Menggunakan Metode Algoritma Tabu Search dan Kilbridge Wester

Abstract

PT Pancaprima Ekabrothers (PPEB) is engaged in the apparel manufacturing industry and a make to order production system for all types of garments produced. The problem experienced is the occurrence of bottlenecks at work stations that affect the imbalance of the trajectory and production output that cannot reach the target of the company. In addition, there is a buildup of semifinished goods in the production track which causes the distribution of the use of funds in the company to be inefficient. The purpose of this research is to obtain a balanced production line to eliminate botlleneck at the workstation. The method used to eliminate bottlenecks in this research is to apply the Theory of Constraint principle using the Tabu Search and Kilbridge-Wester Algorithm methods to balance the production trajectory at each work station. The actual line balancing results of the Ranked Positional Weight (RPW) method are 8 work centers with a line efficiency of 38%, a balance delay of 63%, and a smoothing index value of 3516,65 seconds. The results of balancing the proposed line with the Tabu search algorithm method are 4 work center with a line efficiency of 82%, a balance delay of 19%, and a smoothing index value of 1379,14 seconds. The results of balancing the proposed trajectory with the Kilbridge-wester method are 4 work stations with a line efficiency of 78%, a balance delay of 23%, and a smoothing index value of 1438,53 seconds. Based on the results of actual line balancing with the RPW method and the proposed line balancing by applying the TOC principle using the tabu search and kilbridge-wester algorithm methods, it can be concluded that line balancing using the tabu search method is the best alternative line from the other two methods because it has the smallest balance delay, efficiency, idle time, and smoothing index compared to the other methods and shows the highest time or the heaviest workload can be a reference in work, then providing motivation and control is easier than the initial condition of the production line.