CELLULAR MANUFACTURING DESIGN FOR A321 PROGRAM MACHINING AREA AT DETAIL PART MANUFACTURING DEPARTMENT PT DIRGANTARA INDONESIA

• Main Author: Makmur, Marco
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/69934
• Institution: Institut Teknologi Bandung

PT Dirgantara Indonesia (Persero) is a state-owned business entity engaged in aircraft manufacturing. One of its product is the A321 which is sold to Airbus SE with a product demand of 6 units per month. However, based on the contract between PT Dirgantara Indonesia and Airbus SE, the demand for A321 will gradually increase to 36 units per month over the next few years. The current conditon of PT Dirgantara Indonesia machining area’s productivity won’t be able to keep up to the demand. The biggest cause that contribute to machining area’s low productivity is the number of intercellular moves between workcenter. A single A321 product takes up at least 138 hours of intercellular movements. This number is very large compared to the machining time which is 257 hours per product. Therefore, it is necessary for management to design workcenter cells that minimize intercellular movements. Cellular manufacturing method is used as a reference to classify workcenters in order to minimize intercellular movements. The method is then adjusted to fit the existing characteristics of machining area. It classify workcenters by considering important production parameters such as operations sequence, production volumes, and workcenters capacities. A matrix of 95 components and 14 workcenters of A321 are mapped to help understand the relation of workcenters and components. Similarity coefficient is then calculated between workcenters which is used as a grouping basis to form workcenters’ cell. Pairs with the largest similarity coefficient are grouped into one cell. The iteration stops when all workcenters are grouped into cells. Intercellular movements, relayouting cost, and material handling cost are calculated to determine the designed solution. The designed solution grouped workcenters into 2 cells and relayouting only the first cell. It decrease the intercellular movements from 828 to 162 with Rp 270,520,293 relayouting cost