OPTIMIZING PRODUCTION SCHEDULE BASED ON OVERALL EQUIPMENT EFFECTIVENESS USING GENETIC ALGORITHM TO REDUCE CHANGEOVER (Case Study: at PT MIYU JAYA PERKASA)

• Main Author: Natasha Nindya Putri, Valeria
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/38971
• Institution: Institut Teknologi Bandung

PT MIYU JAYA PERKASA is one the biggest fast moving consumer goods company who produce health food products. With more than 400 SKUs, they face obstacles with the production process efficiency. This can be seen from the value of the Overall Equipment Effectiveness (OEE) of the company by 73.3%, which is still below their own target and international standards. OEE shows a gap of 26.7%, means the production cost is bulging, that can still be optimized so that the production process can be more effective and efficient to achieve the fulfillment target. The methodology used in this study is to use Lean Manufacturing and Six Sigma, as the main concepts that are complementary in analyzing the root cause. Furthermore, business issues were analyzed using the Current Reality Tree, and it was found that the root problem of this study was that they still manually scheduling the production system to manage all products to be produced. This makes the company having the changeover highly at each turn of production. Changeover is done by washing the production line machine every change of product type and set up of the machine every time the product grams is changing. Thus, makes more time wasted and will affect OEE by reducing the operating time. Optimization is done by use the Genetic Algorithm method, optimizing the production schedule for all products in all production lines and arranging/ grouping product by grams’ types on each production line. The optimization results show that by using Genetic Algorithm, the company can reduce production costs for washing the production line/ changeover by 40.7% The author also gave another recommendation, by evaluating the implementation of TPM and considering the replacement of packaging machines into an integrated system so that it is expected that this could further enhance the company's OEE value, especially the plan to transform the production system into fully robotic.