Reduction of Bottleneck in the Jacket Production Process in the Sewing Department using Line Balancing Method
Keywords:Line Balancing, Regional Approach, Workstation Efficiency, Bottleneck
Line Balancing is an assignment of several jobs to the production line or related work stations within the line to minimize idle time. PT ABC is a company engaged in the garment industry that produces products such as Pants, Board shorts, Men-shirts, Ladies wear, T-shirts, Polo shirts and Jackets. The production system used by PT ABC is Make to Order. The company will produce according to the buyer's request. Samples that have been approved will soon be mass-produced. Every day the company produces different products in each line with different targets. Production targets are often not achieved and bottlenecks occur at several work stations, such as in line 2 which produces products in the form of jackets with X style. Therefore, a research was conducted on that line. This study aims to determine the amount of idle time, efficiency, and delay time before and after repairs to determine the optimal work station in the production process of the sewing line 2 department to minimize the occurrence of bottlenecks. This research was conducted using the Regional Approach method. The results of this study resulted in a balanced track design with the number of work stations needed as many as 37 units with an idle time of 5,871.2 seconds, a balance delay of 50.8%, a track efficiency of 49.19% and a smoothness index of 76.59 and an increase in track efficiency which was originally 40.44% to 49.19%.
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