PROPOSING NEW PROCESS DESIGN TO IMPROVE EFFICIENCY OF ENGINE ASSEMBLY PRODUCTION SYSTEM

• Main Author: Maulid Adityo, Majdi
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/53107
• Institution: Institut Teknologi Bandung

PT. XYZ is one of the largest automotive manufacturing company in Indonesia, which currently has a total production capacity of 200,000 units / year to produce superior products in all market segments of four-wheeled vehicles (cars), such as LCGC, LMPV, MPV, City Car, and SUVs. In responding to the increasingly stringent challenges of the automotive business, PT. XYZ always prioritizes high operation efficiency systems in every manufacture of its products with the aim of increasing and maintaining customer satisfaction and customer relationships in accordance with the target market demand every year. In the last 2 years, the value of market demand of PT. XYZ is always fluctuating, which results in the production process being disrupted due to many changes in the work system. Furthermore, preparations for the new products development are continuously being made in order to increase market competition which indirectly also impacts the operational work system, thus demanding the production department at PT. XYZ must create a high efficiency of process design. One of the production departments at PT. XYZ is the Engine Assembly Department, where the process flow of this department in general is the assembly of a car engine starting from the Cylinder Block, Piston, Crankshaft, Cylinder Head and Transmission. There are 4 constituent elements of work process in the Engine Assembly Department, including (1) Part Assembly Time Requirement, a standard for installing parts from DWG or MQS that must be done, (2) Process Guarantee System, a quality assurance system of the assembly process parts that are taken from the rank of each part after the process is carried out, (3) Machine and Tool Requirements, is a need for supporting the assembly process to increase process efficiency and product quality, and (4) Current Process Layout, is an environmental factor that considered when the operator works in the assembly process. These four elements will be brought into the problem analysis based on the Maynard Operation Sequence Technique (MOST) method, where the mismatch of the assembly process at each work point will be continued into a fishbone diagram analysis to find the root cause problem so that it can realize the right improvement. MOST is a work measurement technique that concentrates on a moving object. This method is used to analyze work and to determine the normal time required to perform the work process. Efficient, smooth, and productive work is done when the basic movement patterns are tactical and structured. MOST is very important in assisting and comparing the methods and activities followed in various operations in the industry. The application of the MOST method will be carried out on two models, the current engine production model and the new engine model. In the current engine production model, the application of MOST aims to redesign the assembly process at each work point so, it can increase the efficiency of the existing process. Samples of work points from each production area (4 work stations) are taken and MOST calculations are carried out to proceed into fishbone diagram analysis. The results of the analysis obtained that 2 work stations for improvements to the Machine and Tool Requirement element, 1 work point for improvements to the Process Guarantee System, and 1 work point for improvements to the Current Process Layout. All of the samples of calculated work points, the efficiency process can be stabilized with the target of cycle time (97.7%). In the new engine model, which will start production in ii 2022, the application of MOST is used to determine the design of the assembly process, which is one of the mandatory activities in the process of developing a new engine model. The sample of MOST calculation on a new engine model is done by taking references from the current engine production model process system in all work points of the Engine Assembly Department. The results obtained from this calculation, the Engine Assembly Department must add as many as three operators / shift as a condition for assembling this new engine model inline with a common target of efficiency process. The increment of accuracy of MOST calculation in new engine model, can be carried out during the in-line assembly process of the new engine model, in the form of verification on in-line training activities and the new model event trial. The implementation of MOST in determining a more competitive Engine Assembly process design for these two engine model types will be carried out with the target of implementing the overall improvements completed in June 2021. From this proposal of MOST implementation in Engine Assembly Department, it can be concluded that in current engine production model, all samples of calculated work station can achieve cycle time target. In new engine model, it already defined total number of operators needed to conduct all engine assembly processes by adding three operators / shift. Implementation of MOST can answer the company’s business issues in facing business challenges in the future according to reach target of market demand every year.