PT XYZ is a manufacturing company operating in the tobacco industry, producing goods
to meet the demand of PT HM Sampoerna. Several operational issues have been
identified, particularly within the production process, including the need for overtime work
on Sundays to meet weekly targets, substandard product quality, inadequate worker skill
levels, and limited production capacity. This research specifically focuses on the issue of
overtime work on Sundays, which is attributed to the inconsistency in actual daily
production.
The study employs cycle time data and utilizes time study and work measurement
techniques to calculate standard time. Subsequently, current line efficiency is analysed,
and the Largest Candidate Rule (LCR) method is applied to develop a new workstation
arrangement. Based on these findings, a redesigned production line is proposed and
implemented to evaluate its performance.
The results demonstrate a significant improvement, with line efficiency increasing by
8.32%, from an initial value of 27.68% to 36%. Furthermore, the production capacity of
Zb, the pre-finished product following the packing process, increased by an average of
25%. This enhancement contributes positively to addressing production inconsistencies
and effectively eliminates the need for Sunday overtime work, supporting the potential for long-term operational improvement.