On the Assembly Line Balancing Analysis Unit Motor
Sport Rangked Method Using Positional Weight (RPW) To Optimize
Working Tracks In Pt.Xxx Plant 2 Pegangsaan
Franky Sugiarto
Industrial Engineering Program
University Mercubuana
Campus Meruya Jl. South Meruya Jakarta Kebon Jeruk
Frankysugiarto1@gmail.com
Abstract
(Line Balancing) is a method used to design or improve a line production to becomes
more balanced. Problems that occur in balancing is: about how to determine the optimal
number of work stations, knows the solution to maximize the cycle time that has been
determined the company, and how to determine the trajectory of work.
The method used is Rangked Positional Weight (RPW) method. In the use of this
method is based because there are many idle time during the process of running the operation.
The results obtained from the use of Rangked Positional Weight (RPW) method is
that originally there were 37 stations to 26 work stations, left work stations that initially there
are 37 stations to 27 stations, increasing efficiency right line work station that initially 50% to
71%, left work stations which was originally 53% to 72%. And balance delay is down, the
right work station that initially 50% to 29%, left work station that initially 48% to 28%.
Keywords: Line Balancing, Line Efficiency, Cycle Time, Standard Time
I.PRELIMINARY
In an increasingly global economy crisis, the viability of the industry, both manufactur
industry and the field of services is dependent on how the industry can serve the needs of
customers quickly and produce quality products and services at prices affordable by all
circles of society. Every industry has clearly challenged to improve its performance to
respond quickly and accurately to changes that occur in the market. But still often seen some
products compete with competitors due to the high prices of these products result from
production processes that are ineffective and inefficient.
To answer the challenges of business competition is increasingly fierce, It means the
Industry Manufacture needs to develop and formulate strategies and the exactly production
system. Production System of PT.XXX is Lean Manufacturing the general concept of Lean
Manufacturing is to minimize or eliminate the waste wasteful , but in the field, especially
in Unit 2A LINE Assembly (assembly of motor sport) still waste that occurs in the line, which
is a waste of time assembly unit that can still be diseimbangkkan again so that the assembly
unit 2A does not lose time for the production.
Therefore, one of the factors that determine the order to compete in today's world of
industry is to use the time available as well as possible in order to avoid wastage of time
during the production process. The method used to balance the excess time is to use the Line
Balancing.
See waste-waste that occurs as well as the needs outlined previously, then we can assume
that the line balancing is the right tool if applied at the plant PT.XXX 2 Pegangsaan
especially for motor sport products in order to reduce the waste that occurs.
II.THEORETICAL BASIS
[1] According to Gaspersz (2004; 142), Line balancing is the balancing task assignment
elements of an assembly line to work stations to minimize the number of work stations
and minimize the total idle time (idle time) at all stations for a particular output level.
[2] According to Elwood Buffa (1983; 37), balance is the similarity of output or outcome
or the overall production in each sequence of the production line.
[3] According to Herjanto (1999; 56), line balance is to obtain a smooth production flow
in order to obtain a high utility to the facilities, manpower, and equipment through
balancing work time between work stations.
While [4] According to Bedworth and Bailey (1987; 73), line balancing concept is
beroerientasi problem in manufactur activities relating to masalh resources and resource
balancing.
III.RESEARCH METHODOLOGY
In this study, the writer using two types of methods:
1.
Libraries
Where all materials used in this study was obtained from books, e-books, journals tau
funds related to the themes discussed by the author.
2.
Observation
Where the data used in this study is data taken directly by researchers at 2 Pegangsaan
PT.XXX plant.
IV.RESULTS AND DISCUSSION
In line balancing analysis conducted in PT.XXX plant 2 Pegangsaan, balancing the
resulting gain a more optimal trajectory, where balance delay can be reduced
significantly from previously existing balance delay, which in this study to be conducted
repairs are as follows:
1.
More optimize efficiency trajectory work.
2.
Reducing balance delay.
3.
Do merger station work.
The calculations were performed to obtain the expected result are as follows:
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Stasiun
Kerja
600
601
602
603
604
605
610
611
612
613
614
615
616
617
618
619
620
621
622
623
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
Jumlah
Elemen
Kerja
600
601
602
603
604
605
610
611
612
613
614
615
616
617
618
619
620
621
622
623
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
Ti
(detik)
17.34
13.39
12.23
12.87
11.46
12.24
15.76
10.85
12.08
13.38
16.15
11.71
11.03
8.71
13.75
10.65
11.65
8.27
8.14
12.74
11.90
13.68
12.11
12.71
10.29
11.02
10.79
12.25
13.37
12.56
8.15
12.92
12.17
12.51
11.02
11.51
8.41
441.73
Cycle
Time
24
Idle Time
6.66
10.61
11.77
11.13
12.54
11.76
8.24
13.15
11.92
10.62
7.85
12.29
12.97
15.29
10.25
13.35
12.35
15.73
15.86
11.26
12.10
10.32
11.89
11.29
13.71
12.98
13.21
11.75
10.63
11.44
15.85
11.08
11.83
11.49
12.98
12.49
15.59
446.27
Efficiency
Lintasan
Balance
Delay
50%
50%
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Stasiun
Kerja
702
703
704
705
710
711
712
713
714
715
716
717
718
719
720
721
722
723
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
Jumlah
Elemen
Kerja
702
703
704
705
710
711
712
713
714
715
716
717
718
719
720
721
722
723
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
Ti
(detik)
12.61
12.62
8.09
14.30
16.85
11.65
11.88
10.16
12.53
11.70
11.80
10.15
12.38
12.12
12.20
11.09
12.31
17.79
19.66
11.68
12.35
11.86
11.32
9.58
12.44
12.02
15.04
13.51
12.76
12.64
14.24
12.21
10.96
11.23
11.49
12.56
18.82
468.63
Cycle
Time
24
Idle Time
11.39
11.38
15.91
9.70
7.15
12.35
12.12
13.84
11.47
12.30
12.20
13.85
11.62
11.88
11.80
12.91
11.69
6.21
4.34
12.32
11.65
12.14
12.68
14.42
11.56
11.98
8.96
10.49
11.24
11.36
9.76
11.79
13.04
12.77
12.51
11.44
5.18
419.37
Efficiency Balance
Lintasan
Delay
53%
47%
After knowing the trajectory of efficiency and balance delay assembly unit in
PT. XXX Plant 2 in Pegangsaan, then be further improvements of efficiency to become more
optimal trajectory, that is by combining the work stations in the company with a record
should not cross the line cycle time specified by the company. Here is the formula used to
calculate the efficiency of the track and the formula for calculating the balance delay in order
to optimize the trajectory of the current work.
Tracks efficiency =
𝐸𝑓𝑖𝑠𝑖𝑒𝑛𝑠𝑖 𝐿𝑖𝑛𝑖 =
∑𝑛𝑖=1 𝑡𝑖
𝑥 100%
𝐶𝑇 𝑥 𝑁
Description:
n = number of elements of the existing work.
CT = Cycle Time (Cycle Time).
N = Total Work Station formed.
Delay Balance:
𝑏𝑎𝑙𝑎𝑛𝑐𝑒 𝑑𝑒𝑙𝑎𝑦 =
𝐶𝑇 𝑥 𝑁−∑𝑛
𝑖=1 𝑡𝑖
𝐶𝑇 𝑥 𝑁
𝑥 100%
Table 4. 3 Work Right After Repair Station
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Stasiun
Kerja
600
601
602
603
604
605
610
611
612
613
614
615
616
617
618
619
620
621
622
623
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
Jumlah
Elemen
Kerja
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Ti
Ti setelah
(detik) digabung
17.34 17.34
13.39 13.39
12.23 12.23
12.87 12.87
11.46
23.69
12.24
15.76 15.76
10.85
22.93
12.08
13.38 13.38
16.15 16.15
11.71
22.73
11.03
8.71
22.47
13.75
10.65
22.30
11.65
8.27
16.40
8.14
12.74 12.74
11.90 11.90
13.68 13.68
12.11 12.11
12.71
23.00
10.29
11.02
21.81
10.79
12.25 12.25
13.37 13.37
12.56
20.71
8.15
12.92 12.92
12.17 12.17
12.51
23.53
11.02
11.51
19.92
8.41
441.7
441.7
Cycle Time Idle Time
24
6.66
10.61
11.77
11.13
12.54
11.76
8.24
13.15
11.92
10.62
7.85
12.29
12.97
15.29
10.25
13.35
12.35
15.73
15.86
11.26
12.10
10.32
11.89
11.29
13.71
12.98
13.21
11.75
10.63
11.44
15.85
11.08
11.83
11.49
12.98
12.49
15.59
Efficiency
lintasan
Balance
Delay
71%
29%
Table 4. Left 4 Work Station After Repair Guide
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Stasiun
Kerja
702
703
704
705
710
711
712
713
714
715
716
717
718
719
720
721
722
723
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
Jumlah
Elemen
Kerja
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Ti
Ti setelah
(detik) digabung
12.61
12.61
12.62
20.71
8.09
14.30
14.30
16.85
16.85
11.65
23.53
11.88
10.16
22.68
12.53
11.70
23.51
11.80
10.15
22.53
12.38
12.12
12.12
12.20
23.29
11.09
12.31
12.31
17.79
17.79
19.66
19.66
11.68
11.68
12.35
12.35
11.86
23.18
11.32
9.58
22.02
12.44
12.02
12.02
15.04
15.04
13.51
13.51
12.76
12.76
12.64
12.64
14.24
14.24
12.21
23.17
10.96
11.23
22.73
11.49
12.56
12.56
18.82
18.82
468.6
468.6
Cycle
Time
Idle Time
Efficiency
lintasan
Balance
Delay
72%
28%
11.39
3.29
9.70
7.15
0.47
1.32
0.49
1.47
11.88
0.71
24
11.69
6.21
4.34
12.32
11.65
0.82
1.98
11.98
8.96
10.49
11.24
11.36
9.76
0.83
1.27
11.44
5.18
Analysis

Reduced
of
balance
amount
sufficient
delay significant can create company become more good in use time in
order
to advance productivity company.

On line balancing analysis, the company could use method rangked positional
weight (RPW) to more optimize again station existing work in order to
be more efficientagain.
Result
Analysis results obtained after the processing of the data is as follows

Station working Right is initially there are 37 stations, after do processing the
data into 26 stations.

Station working initially left there are 37 stations, after do then data
processing station to 27 stations.

Efficiency trajectory working station right before repair is
50%,
after do repair become ie 71% more optimal.

Efficiency trajectory working station right before repair is
53%,
after do repair become ie 72% more optimal.

Balance station delay acquired right before repair is by 50%, then diminish to
29%.

Balance station delay right before the improvement was obtained by 47%,
then diminish to 28%.
V.CONCLUSIONS AND SUGGESTIONS
Conclusion
Based on the analysis that has been performed by the authors, it can be concluded
as follows:
1.
To optimizing
existing
time is with way combine station working become more a little.
cycle
2.
To making assembly line units to more efficient can views on Table 4.24 and
the 4:25
table,
at
the
table mentioned can views result from efficiency trajectory after useRPW method.
3.
Based
on number reduction station work,
then number station
formed become more optimal, it mentioned can be evidenced on Figure 4.3 precedence
diagram afterrepair.
Suggestion
The advice given by the author to the company as consideration for the follow-up is as
follows:
1.
Companies
can use method Rangked
Positional
Weight
(RPW),
so lessening station can work provide impact positive to job processing time.
2.
Companies should do continuous improvement in order to gain more optimal
trajectory again.
3.
Companies should provide more motivation so that the operator does not
feel overwhelmed in work.
VI.BIBLIOGRAPHY
[1] Baroto. (2002). Planning and Production Control, Issue 1. Jakarta: Ghalia
Indonesia.
[2] Bedworth, David D. and James E. Baeley. (1987). Integrated Production Control
Systems Management, Analysis, Design, (2 nd ed) John Wiley & Sons, New York.
[3] Bigel, John E. (1992). Production Control: A Quantitative Approach. Akademikia
Pressindo, Jakarta.
[4]
Buffa,
Elwood.
(1983). Modern
Production
/
Operations
th
Management. (7 ed). John Wiley & Sons, New York.
[5] Gaspersz, Vincent. (2004). Planning Production And Inventory Control. Scholastic
Public Library, Jakarta.
[6] Herjanto, Eddy. 1999. Production and Operations Management. Jakarta: Indonesia
Widiasarana PT.Gramedia.
[7] Hussein, torik. Analysis and Design of Work. 2014 Jakarta: Department of
Industrial Engineering Faculty of Engineering, University of Mercubuana.
[8] Liker, David Meier. (2006). The Totoya Was Fieldbook. Publisher, Jakarta.