THEORY-OF-CONSTRAINTS-BASED HEURISTIC METHOD PROPOSED FOR FLEXIBLE FLOW SHOP SCHEDULING IN PT KIMIA FARMA (PERSERO) TBK PLANT BANDUNG

• Main Author: VANDYANI ARDIYANTO, RAHMANISA
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/43182
• Institution: Institut Teknologi Bandung

PT Kimia Farma (Persero) Tbk. is a state-owned entreprises (BUMN) in Indonesia that is active in healthcare industry. One of their business lines is pharmaceutical manufacturing. Tablet is one of their highly-requested product to be produced in Bandung plant. Overtime is often needed to fulfill the demand for tablet. Based on the analysis, this condition happens due to the poor scheduling system because there is no systematic procedure for scheduling the production process. It is indicated by the high number of makespan, low average percentage of machine utilization, and high number of major cleaning needed. Therefore, this research aims to propose a scheduling method that can minimize makespan so that overtime can also be reduced. Production system that is used to produce tablets is a flexible flow shop system with 9 production stages. Each stage has different number of parallel machine. Those parallel machines could have different capacity and specification so that not all machine could be used to manufacture all types of tablet. Method that is used to clean the production machines may vary depend on the sequence of the job, therefore it can be called as a sequence dependent system. Scheduling method that is proposed in this research is a heuristic method named Theory of Constraints (TOC) that has been developed and adjusted with the actual condition. This method is then applied to the company’s demand data for January 2018 and can reduce makespan for manufacturing 61 batches of tablets from 597,86 hours to 568,81 hours so that the overtime needed can be reduced by 3 days. This reduction of makespan also followed by the increased of average machine utilization from 52,88% to 56,80% and the decreased number of major cleaning needed from 168 to 143.