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Perbaikan Keseimbangan Lintasan Bagian Final Assembly Water Pump Business Unit Model X Dengan Menggunakan Metode Theory of Constraint Dan Tabu Search Pt

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Perbaikan Keseimbangan Lintasan Bagian Final Assembly Water Pump Business Unit Model X Dengan Menggunakan Metode Theory of Constraint Dan Tabu Search Pt PERBAIKAN KESEIMBANGAN LINTASAN BAGIAN FINAL ASSEMBLY WATER PUMP BUSINESS UNIT MODEL X DENGAN MENGGUNAKAN METODE THEORY OF CONSTRAINT DAN TABU SEARCH PT. PMI TUGAS SARJANA Diajukan untuk Memenuhi Sebagian dari Syarat-syarat Memperoleh Gelar Sarjana Teknik oleh GRETTY MARGARETHA NIM. 120403179 DEPARTEMEN TEKNIK INDUSTRI FAKULTAS T E K N I K UNIVERSITAS SUMATERA UTARA M E D A N 2 0 1 7 I-1 UNIVERSITAS SUMATERA UTARA I-2 PERBAIKAN KESEIMBANGAN LINTASAN BAGIAN FINAL ASSEMBLY WATER PUMP BUSSINESS UNIT MODEL X DENGAN MENGGUNAKAN METODE THEORY OF CONSTRAINT DAN TABU SERACH PADA PT. PMI TUGAS SARJANA Diajukan untuk Memenuhi Sebagian dari Syarat-syarat Memperoleh Gelar Sarjana Teknik Oleh GRETTY MARGARETHA 120403179 Disetujui Oleh Dosen Pembimbing I Dosen Pembimbing II (Dr. Ir. Listiani Nurul Huda, M.Eng) (Ikhsan Siregar, S.T, M.Eng) D E P A R T E M E N T E K N I K I N D U S T R I F A K U L T A S T E K N I K UNIVERSITAS SUMATERA UTARA M E D A N 2017 UNIVERSITAS SUMATERA UTARA I-3 KATA PENGANTAR Puji dan syukur penulis ucapkan kehadirat Tuhan Yang Maha Esa karena atas Rahmat dan Karunia-Nya, penulis dapat menyelesaikan Tugas Sarjana ini dengan baik. Penulisan Tugas Sarjana ini adalah bertujuan untuk memenuhi salah satu syarat akademis yang harus dipenuhi oleh mahasiswa dalam menyelesaikan studi di Departemen Teknik Industri, Fakultas Teknik, Universitas Sumatera Utara. Dalam hal ini, penulis meneliti di lantai produksi pada PT. PMI yang bergerak di bidang elektronik. Tugas Sarjana ini berjudul “Perbaikan Keseimbangan Lintasan Bagian Final Assembly Water Pump Business Unit Model X dengan Menggunakan Metode Theory Of Constraint Dan Tabu Search PT. PMI” Penulis menyadari bahwa tugas sarjana ini belum sepenuhnya sempurna. Oleh karena itu, penulis mengharapkan kritik dan saran yang membangun dari pembaca untuk kesempurnaan Tugas Sarjana ini. Akhir kata, penulis berharap agar Tugas Sarjana ini bermanfaat bagi semua pihak yang membutuhkannya. UNIVERSITAS SUMATERA UTARA, MEDAN PENULIS. Januari 2017 UNIVERSITAS SUMATERA UTARA I-4 UCAPAN TERIMA KASIH Segala puji dan syukur penulis ucapkan yang sebesar-besarnya kepada Tuhan Yang Maha Esa yang telah memberikan kesempatan kepada penulis untuk dapat mengikuti pendidikan di Departemen Teknik Industri USU serta telah memberikan nikmat kesehatan dan ilmu kepada penulis selama masa kuliah dan penulisan laporan tugas sarjana ini. Dalam penulisan tugas sarjana ini penulis telah mendapatkan bimbingan dan bantuan dari berbagai pihak, baik berupa materil, spiritual, informasi maupun administrasi. Oleh karena itu sudah selayaknya penulis mengucapkan terima kasih kepada: 1. Ibu Dr. Ir. Listiani Nurul Huda, M.Eng selaku Dosen Pembimbing I dan Bapak Ikhsan Siregar, S.T, M.Eng selaku Dosen Pembimbing II atas waktu, bimbingan, pengarahan, dan masukan yang diberikan kepada penulis dalam penyelesaian Tugas Sarjana ini. 2. Ibu Ir. Khawarita Siregar, M.T. selaku Ketua Departemen Teknik Industri Universitas Sumatera Utara dan Bapak Ir. Ukurta Tarigan S.T sekalu Sekertaris Departemen Teknik Industri Universitas Sumatera Utara 3. Orang tua saya, Selle Dorlina Sitorus yang tiada hentinya mendukung penulis baik secara moril maupun materil, serta senantiasa mendoakan sehingga laporan ini dapat diselesaikan dan abang Hesekiel Morsa yang telah memberikan segala jenis dukungan dalam mengerjakan laporan ini. 4. Bapak A. Kholikh selaku Pembimbing Lapangan serta karyawan di PT. PMI yang telah memberikan bantuan selama penelitian. 5. Seluruh dosen Departemen Teknik Industri, Fakultas Teknik, Universitas Sumatera Utara yang telah memberikan pengajaran selama perkuliahan yang menjadi bekal dalam penulisan tugas sarjana ini. UNIVERSITAS SUMATERA UTARA I-5 6. Untuk teman-teman terkasih: Adella Sirait, Jenniver, Dian Labora, Mutiara Sembiring, dan Anita buat saran, semangat dan bantuannya selama ini. 7. Teman seperjuangan Sarah Octaviola yang senantiasa memotivasi, memberi masukan, dan mendoakan saya hingga sampai di tahap ini. 8. Rekan-rekan Asisten Laboratorium Pengukuran dan Statistik Teknik Industri 2012 Laxhmi, Yuli, Arifin, Mike, Adelia, Freddy dan Arif yang telah banyak memerikan masukan yang baik terhadap laporan ini. 9. Rekan-rekan mahasiswa Teknik Industri Stambuk 2012 (DUA BELATI) serta abang kakak senior dan junior yang tidak dapat ditulis satu persatu yang telah memberikan motivasi dan doanya selama penulis menjalani tugas akhir. 10. Adik-adik Laboratorium Pengukuran dan Statistik 2013 Haura, Ica, Jean, Sri, Gabriel, dan liwanto serta yang selalu mendukung penyelesaian laporan ini. Kepada seluruh pihak yang telah banyak memberi bantuan kepada penulis dalam penyelesaian tugas sarjana ini yang tidak dapat disebutkan satu per satu, penulis mengucapkan terimakasih. Semoga laporan tugas sarjana ini dapat bermanfaat bagi kita semua Medan, Januari 2017 Penulis UNIVERSITAS SUMATERA UTARA I-6 ABSTRAK PT. PMI adalah sebuah perusahaan manufaktur yang bergerak dalam bidang elektronik. Perusahaan menerapkan sistem produksi yang dimulai dari barang setengah jadi menjadi finish good product. Jenis produk yang dihasilkan adalah Audio, Electric Fan, Water Pump, Refrigerator, Laundry System, Air Conditioner dan Production Engineering. Focus penelitian dilakukan terhadap water pump bussines unit. Jumlah permintaan water pump adalah yang tertinggi setiap bulannya. Masalah yang dihadapi perusahaan adalah penumpukan work in process (WIP) dan ketidakseimbangan lintasan produksi. Keseimbangan lintasan pada final assembly akan mempengaruhi jumlah produk yang dapat dihasilkan. Kondisi lintasan yang tidak seimbang mengakibatkan bottleneck pada aliran material dari satu work center ke work center berikutnya, sehingga terjadi waktu menunggu (delay time) dan penumpukan material (work in process) di lantai produksi. Hal ini terjadi disebabkan oleh perbedaan waktu siklus yang cukup besar sehingga menyebabkan perbedaan kapasitas produksi untuk setiap work center. Metode stopwatch time study digunakan untuk mendapatkan waktu standar tiap elemen kegiatan. Penerapan theory of constraints digunakan untuk mengidentifikasi kendala yang ada dan untuk mendapatkan jumlah work center yang optimum, serta algoritma tabu search digunakan untuk mengalokasi elemen kegiatan pada tiap work center dan meningkatkan efisiensi lintasan produksi. Pada lintasan aktual terdapat 7 work center dengan 10 orang tenaga kerja, memiliki efesiensi lintasan 59,80%, balance delay 40,20%, dan smoothing index 74,47. Hasil penyeimbangan lintasan produksi dengan menggunakan metode algoritma tabu search diperoleh 5 work center dengan 7 orang tenaga kerja, dan memiliki efisiensi lintasan 88,65%, balance delay 11,35%, dan smoothing index 17,07. Kata Kunci: Bottleneck, Line Balancing, Theory Of Constraints, Tabu Search. UNIVERSITAS SUMATERA UTARA I-7 DAFTAR ISI BAB HALAMAN LEMBAR JUDUL .................................................................................................. i LEMBAR PENGESAHAN ................................................................................... ii SERTIFIKAT TUGAS SARJANA ....................................................................... iii KATA PENGANTAR ............................................................................................ iv UCAPAN TERIMA KASIH .................................................................................. v ABSTRAK .............................................................................................................. vii DAFTAR ISI .......................................................................................................... viii DAFTAR TABEL .................................................................................................. xii DAFTAR GAMBAR ............................................................................................. xiv DAFTAR LAMPIRAN ......................................................................................... xvi I PENDAHULUAN 1.1. Latar Belakang ................................................................................................ I-1 1.2. Perumusan Masalah ....................................................................................... I-5 1.3. Tujuan dan Manfaat ....................................................................................... I-5 1.4. Batasan dan Asumsi Penelitian ....................................................................... I-6 1.5. Sistematika Penulisan Laporan ....................................................................... I-7 II GAMBARAN UMUM PERUSAHAAN 2.1. Sejarah Perusahaan ......................................................................................... II-1 2.2. Ruang Lingkup Bidang Usaha ........................................................................ II-4 2.3. Lokasi Perusahaan .......................................................................................... II-5 2.4. Daerah Pemasaran .......................................................................................... II-5 2.5. Proses Produksi ............................................................................................... II-6 2.5.1. Bahan Utama ................................................................................... II-6 2.5.2. Bahan Tambahan ............................................................................. II-7 2.5.3. Bahan penolong ............................................................................... II-8 DAFTAR ISI (LANJUTAN) BAB HALAMAN 2.6. Mesin Produksi ..............................................................................................
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